Automatic vibratory separator

ABSTRACT

Methods for automatically controlling a vibratory separator, e.g., but not limited to a shale shaker for processing drilling fluid, the methods in certain aspects including: introducing material to a vibratory separator; sensing with sensor apparatus a state parameter indicative of operation of the vibratory separator; providing a signal indicative of a value of said state parameter to control apparatus; and, with the control apparatus, automatically controlling the vibratory separator based on the level of the state parameter. This abstract is provided to comply with the rules requiring an abstract which will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure and is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a continuation of U.S. application Ser. No. 12/481,959, filedJun. 10, 2009, which is a division of U.S. application Ser. No.11/977,727, filed Oct. 25, 2007, which is a division of U.S. applicationSer. No. 11/096,192, filed Mar. 31, 2005, which is: acontinuation-in-part of U.S. application Ser. No. 10/949,882, filed Sep.25, 2044, issued as U.S. Pat. No. 7,278,540 on Oct. 9, 2007; acontinuation-in-part of U.S. application Ser. No. 10/835,256, filed Apr.29, 2004, issued as U.S. Pat. No. 7,331,469 on Feb. 19, 2008; acontinuation-in-part of U.S. Ser. No. 10/512,372, filed Oct. 25, 2004,issued as U.S. Pat. No. 7,581,647 on Sep. 1, 2009, which is a 371 ofApplication Ser. No. PCT/IB03/01031, filed Mar. 12, 2003, which claimspriority from U.S. Ser. No. 10/134,027, filed Apr. 26, 2002; and acontinuation-in-part of U.S. Ser. No. 10/373,216, filed Feb. 24, 2003,which claims priority from U.S. Provisional Application Ser. No.60/424,262, filed Nov. 6, 2002—all of which are incorporated fullyherein and with respect to all of which the present invention andapplication claims priority under the Patent Laws.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention is directed to vibratory separators and shale shakers; toapparatuses and methods for sensing various parameters related to theuse of separators and shakers, including, but not limited to, fluidlevels in such separators; and to apparatuses and methods for adjustingsuch levels and for adjusting the extent of a beach area on a screen.

2. Description of the Related Art

In many prior art vibratory separators and shale shakers a pool or massof fluid or material is formed on top of one or more screens or screenassemblies which are used to filter material introduced to the separatoror shaker. The depth of this fluid or material can affect efficientoperation of the separator or shaker. Fluid or material that is too deepmay not be adequately filtered. Fluid or material that is too shallowmay flow across a screen too quickly or without sufficient weight to befiltered adequately.

Shale shakers assist in maintaining certain desired properties ofdrilling fluid by using vibrating screens to remove certain largeparticles while allowing certain smaller particles to remain in thefluid. The large undesirable particles may include drilling cuttings anddebris picked up in the drilling process. The smaller particles mayinclude drilling fluid additives that are required for maintainingdesired drilling fluid density and viscosity. The screens on theseshakers have a limited life, and can be expensive and time consuming toreplace. The shaker is turned off and, preferably, rinsed clean prior toscreen replacement.

One factor in screen life is how well the beach area is maintained.“Beach” area is the distance from a fluid-dry interface-with-fluid lineon a final screen to the end of the screen. Thus, a zero beach lengthdescribes a shaker operating with drilling fluid covering the entirescreen area of the final screen and running over to discharge. This canbe costly due to the loss of drilling fluid which flows off, rather thanthrough, a screen. A beach length of 20″ in certain shakers indicates ashaker operating fairly dry, with the last sections of screenpotentially vibrating against completely dry particles. Such dryparticles vibrating on the beach of the last screen can tear holes inthe screen and shorten the screen life. The beach length is affected byvariables such as fluid flow rates and drilling fluid propertiesincluding viscosity, density, temperature, and solids content.

In many prior art separators and shakers tilting or raising mechanismsare provided to adjust the angle of screen(s) with respect to thehorizontal. For example, a prior art shaker S (shown in FIG. 1) has atilting mechanism which permits a screen-containing basket to be tiltedaround a pivot point P up to 5 from the horizontal.

U.S. Pat. No. 4,082,657 discloses a separator apparatus which hasindividual height adjustable mounting structures for each screen unitwhich permit adjustment of the screen unit angle with respect to thehorizontal.

U.S. Pat. No. 6,575,304 B2 discloses a hydraulic ram apparatus beneath ascreen body which is used to adjust the angle of incline of the screenbody.

In many prior art systems, a determination of the level of material orfluid on a screen or screen assembly of a separator or shaker is donevisually and then adjustments of screen incline angle or of screensupport incline angle are done manually.

There has long been a need, recognized by the present inventors, toprovide an efficient and accurate measurement of the depth of fluid ormaterial on a screen or screen assembly of a vibratory separator orshale shaker. There has long been a need, recognized by the presentinventors, for such separators and shakers with accurate adjustment ofsuch depth based on measurement thereof. There has long been a need,recognized by the present inventors, for a shale shaker or vibratoryseparator with screen pool depth adjustability to efficiently adjustlast-screen beach extent to enhance screen efficiency and to prolongscreen life.

BRIEF SUMMARY OF THE INVENTION

The present invention, in certain embodiments, a shale shaker orvibratory separator with a base; a basket movably mounted on the baseand for supporting screen apparatus for treating material introduced ata first end of the basket into the vibratory separator, the basket on abase and the first end pivotable with respect thereto, the basket havinga second end spaced apart from the first end, material exiting thebasket at the second end; vibratory apparatus connected to the basketfor vibrating the basket; screen apparatus supported by the basket, thematerial flowing onto the screen apparatus for treatment; angleadjustment apparatus connected to the basket for adjusting angle of thebasket by pivoting the basket's first end; sensor apparatus connected tothe vibratory separator for sensing a parameter indicative of basketangle and for providing a signal corresponding to said basket angle;control apparatus for receiving signals from the sensor apparatus andfor controlling basket angle based on said signals; and the angleadjustment apparatus including movement apparatus for moving the secondend up and down to change basket angle, the movement apparatuscontrolled by the control apparatus.

The present invention, in certain aspects, discloses a vibratoryseparator with a base; a basket movably mounted on the base and forsupporting screen apparatus for treating material introduced into thevibratory separator, the basket on a base and pivotable with respectthereto; vibratory apparatus connected to the basket for vibrating thebasket; screen apparatus supported by the basket, the material flowingonto the screen apparatus for treatment; angle adjustment apparatusconnected to the basket for adjusting angle of the basket; sensorapparatus for sensing a parameter indicative of basket angle and forproviding a signal corresponding to said basket angle; control apparatusfor receiving signals from the sensor apparatus and for controllingbasket angle based on said signals; the angle adjustment apparatusincluding a rocker arm assembly with a first end and a second end, thefirst end pivotably mounted to the base adjacent and beneath a materialinput area of the vibratory separator and the second adjacent andbeneath a material exit end of the vibratory separator; and the angleadjustment apparatus including movement apparatus with a part thereof incontact with the second end of the rocker arm assembly for moving thesecond end up and down to change basket angle, the movement apparatuscontrolled by the control apparatus.

The present invention discloses, in certain embodiments, beachadjustment apparatus for adjusting extent of a beach on a screen of avibratory separator, the screen mounted to a vibratable basket of thevibratory separator, the beach adjustment apparatus having anend-pivotable basket support for supporting the basket, theend-pivotable basket support pivotable at a pivot end thereof, the endpivotable basket support having a second end spaced-apart from the pivotend, the second end positionable near an exit end of a vibratoryseparator, apparatus for pivoting the end-pivotable basket support atits pivot end, and the apparatus for pivoting the end-pivotable basketsupport including movement apparatus for moving the second end of theend-pivotable basket support for facilitating pivoting movement of theend-pivotable basket support to raise and lower the second end to adjustthe extent of the beach.

The present invention, in certain embodiments, teaches a vibratoryseparator (in one particular aspect, a shale shaker) which has sensingapparatus for sensing parameters indicative of the level of fluid ormaterial on a screen or screen assembly supported by the separator and,therefore, for indicating the extent of a beach area on the screen orscreen assembly. In one aspect, a screen or screen assembly itself (or ascreen on holding structure) is able to be inclined to a desired angleto adjust the extent of a beach area adjacent an exit end of a screen. Abeach area is an area adjacent a screen's exit end with two boundarysides—a first side (or rear side) is the side of a pool of material onthe screen (analogous to the seashore) and the second side or front sideis at or near the exit end of the screen. It is important in somesystems to maintain a beach area of desired extent which is sufficientlylarge so that the pool does not extend to or beyond the screen's exitend—which would result in some material not being treated (filtered,separated) by the screen and simply flowing off the end of the screen.It is also important in some systems to insure that the beach area isnot too large which could adversely affect screening efficiency andeffectiveness.

In certain aspects, such a separator also has adjustment apparatus(powered electrically, hydraulically, or pneumatically) for receivinginformation from one or more sensing apparatuses regarding distance tofluid or material at a certain location on a screen or screen assembly(which corresponds to pool depth at the location) and for then adjustingincline angle of the screen or screen assembly to adjust and maintainthe extent of a beach area adjacent an exit end of a screen

In certain aspects, any suitable basket pivot point is used from abasket center to a basket end. In one particular aspect a basket forsupporting a screen or screen assembly is positioned and configured sothat it pivots at a pivot point relatively near one of its ends; and, inone particular aspect, such a pivot is beneath a rear line which is therear boundary of a desired beach area (“rear” meaning the beach boundaryfarthest away from the exit end of a screen).

The present invention, in certain aspects, discloses a shale shaker orvibratory separator with a screen support or basket for supportingscreen apparatus for treating material introduced into the vibratoryseparator, the basket on a base and pivotable with respect thereto;vibratory apparatus connected to the basket for vibrating the basket;screen apparatus supported by the basket, the material flowing onto thescreen apparatus and forming a pool on the screen apparatus, and a beachon the screen apparatus adjacent the pool; measurement sensor apparatusconnected to the vibratory separator and positioned above the screenapparatus for measuring a distance from the measurement sensor apparatusto a top surface of the pool, the measurement sensor apparatus includinga signal production portion for producing signals indicative of saiddistance and for transmitting said signals; a control system forcontrolling and in communication with the measurement sensor apparatusfor receiving signals from the measurement sensor apparatus indicativeof said distance and for processing said signals to calculate a pooldepth corresponding to said distance, said pool depth related to alocation of an edge of said pool adjacent said beach; and angleadjustment apparatus connected to the basket and controlled by thecontrol system for adjusting angle of the basket, thereby adjustingextent of the beach.

In one particular aspect, a shale shaker according to the presentinvention consists of a vibrating basket which supports multiplescreens. Drilling fluid is directed to flow over the screens from a weirtank. As fluid flows over the screens, drilling fluid and smallerparticles pass through the screens and are returned to the drillingfluid system. The larger particles and pieces remain on top of thescreens, and vibratory action moves them off an end of the shaker.Within the shaker, the angle at which the basket sits can be changed tomaintain the desired beach area. One or more ultrasonic transducersensor measuring apparatuses mounted above a screen or screens, (in oneaspect above the last screen) measures the fluid level on screen(s) oron the last screen.

In one particular aspect a single sensor is used above the pool above alast screen which is a pool area that is less turbulent than previousscreen areas and, in one aspect, a basket pivot point is located beneatha beach's rear line so that the single sensor provides all neededinformation to adjust beach extent as desired. The level of the fluid onthe screen(s) is related to the rear or inner beach boundary. A signalfrom the sensor(s) indicative of sensor-to-pool-surface distance is sentto a control system, e.g. a computerized control system, a programmablelogic controlled control system, a digital signal processor and/or amicroprocessor based control system which interprets the signal andsends a control signal to a height adjustment apparatus, e.g., but notlimited to, a system with a directional control valve which controlspressurized hydraulic fluid flow to pistons attached via linkagesbetween the shaker base and basket and/or any basket raising apparatus(mechanical, pneumatic, or hydraulic; e.g. but not limited tohydraulically-powered piston/cylinder apparatuses) of the prior art. Incertain aspects, multiple distance measurements are made and thecontroller is programmed to average the measurements. As the basket israised or lowered, the basket angle changes. When the beach width is toolong, the height adjustment apparatus decreases the angle of the basket,and when the beach width is too short, the angle of the basket isincreased. Thus, the desired beach extent is automatically maintained. Adesired sensor-to-pool-surface distance, and thus a desired beach widthcan be programmed into the control system for a particular separator,shaker, screen, or screen assembly.

In one particular aspect a power system for providing hydraulic fluidunder pressure to apparatus for raising and lowering a basket usesdouble rod hydraulic cylinders so that dual apparatuses on two sides ofa basket operate in unison. One or more sensors may be connected to orover a basket, to a rear tank, to a skid or base, or to a motor tube ormount. In one aspect a fluid reservoir (hydraulic fluid or gas) and/orfluid pump apparatus is part of a vibratory separator system or part ofa shale shaker. In one particular aspect, a skid, base, or support of ashaker or part of a shaker supports a fluid reservoir; and pumpapparatus on the shaker provides fluid to height adjustment apparatus.

In certain aspects a fluid flow sensor is employed on a vibratoryseparator or shale shaker which gives an indication when the flow ofmaterial ceases so that a basket end near a material input point can belowered so that upon recommencement of the material flow the basketangle is such that material does not flow off a last screen's exit endwithout being treated.

In certain aspects the present invention provides a vibratory separator(e.g. but not limited to a shale shaker) with a basket for supportingscreen apparatus for treating material introduced into the vibratoryseparator, the basket on a base and pivotable with respect thereto;vibratory apparatus connected to the basket for vibrating the basket andthe screen apparatus in the basket; screen apparatus supported by thebasket, the material flowing onto the screen apparatus and forming apool on the screen apparatus, and a beach formed on the screen apparatusadjacent the pool; measurement sensor apparatus connected to thevibratory separator and positioned above the screen apparatus formeasuring a distance from the measurement sensor apparatus to a topsurface of the pool, the measurement sensor apparatus including a signalproduction portion for producing signals indicative of said distance andfor transmitting said signals; a control system for controlling and incommunication with the measurement sensor apparatus for receivingsignals from the measurement sensor apparatus indicative of saiddistance and for processing said signals to calculate a pool depthcorresponding to said distance, said pool depth related to a location ofan edge of said pool adjacent said beach; and angle adjustment apparatusconnected to the basket and controlled by the control system foradjusting angle of the basket, thereby adjusting extent of the beach.

Accordingly, the present invention includes features and advantageswhich are believed to enable it to advance vibratory separatortechnology. Characteristics and advantages of the present inventiondescribed above and additional features and benefits will be readilyapparent to those skilled in the art upon consideration of the followingdetailed description of preferred embodiments and referring to theaccompanying drawings.

What follows are some of, but not all, the objects of this invention. Inaddition to the specific objects stated below for at least certainpreferred embodiments of the invention, there are other objects andpurposes which will be readily apparent to one of skill in this art whohas the benefit of this invention's teachings and disclosures. It is,therefore, an object of at least certain preferred embodiments of thepresent invention to provide new, unique, useful, and nonobvious systemsand methods of their use—all of which are not anticipated by, renderedobvious by, suggested by, or even implied by any of the prior art,either along or in any possible legal combination; and it is, therefore,an object of at least certain preferred embodiments of the presentinvention to provide:

New, useful, unique, efficient, non-obvious vibratory separators andshale shakers and methods of their use;

Such separators and shakers with one or more sensing apparatuses forsensing parameters indicative of the depth of fluid or material onscreen(s) or screen assemblies supported by the separator or shaker,which depth is related to the extent of a beach area on the screen(s) orscreen assemblies;

Such separators or shakers with a screen support which is pivotable ator near one of its ends for screen inclination angle adjustment therebyadjusting beach area;

Such separators or shakers with adjustment apparatus for adjustingscreen inclination angle based on information received from the sensingapparatus or apparatuses;

Such separators or shakers with sensor(s) to sensesensor-to-pool-surface distance on screen(s) and to automatically adjustsaid distance to maintain a desired beach extent on a screen; and, inone aspect, on a last or material-exit screen; and, in one aspect, asingle sensor which, in certain embodiments, is located above a basketpivot point;

Such separators or shakers with material flow sensing apparatus so thatbasket angle can be adjusted and readjusted depending on the materialflow status; and

New, useful, unique, efficient, non-obvious beach adjustment apparatusfor adjusting beach extent on a screen of a vibratory separator or shakeshaker.

Certain embodiments of this invention are not limited to any particularindividual feature disclosed here, but include combinations of themdistinguished from the prior art in their structures, functions, and/orresults achieved. Features of the invention have been broadly describedso that the detailed descriptions that follow may be better understood,and in order that the contributions of this invention to the arts may bebetter appreciated. There are, of course, additional aspects of theinvention described below and which may be included in the subjectmatter of the claims to this invention. Those skilled in the art whohave the benefit of this invention, its teachings, and suggestions willappreciate that the conceptions of this disclosure may be used as acreative basis for designing other structures, methods and systems forcarrying out and practicing the present invention. The claims of thisinvention are to be read to include any legally equivalent devices ormethods which do not depart from the spirit and scope of the presentinvention.

The present invention recognizes and addresses the problems and needs inthis area and provides a solution to those problems and a satisfactorymeeting of those needs in its various possible embodiments andequivalents thereof. To one of skill in this art who has the benefits ofthis invention's realizations, teachings, disclosures, and suggestions,other purposes and advantages will be appreciated from the followingdescription of certain preferred embodiments, given for the purpose ofdisclosure, when taken in conjunction with the accompanying drawings.The detail in these descriptions is not intended to thwart this patent'sobject to claim this invention no matter how others may later attempt todisguise it by variations in form, changes, or additions of furtherimprovements.

The Abstract that is part hereof is to enable the U.S. Patent andTrademark Office and the public generally, and scientists, engineers,researchers, and practitioners in the who are not familiar with patentterms or legal terms of phraseology to determine quickly from a cursoryinspection or review the nature and general area of the disclosure ofthis invention. The Abstract is neither intended to define theinvention, which is done by the claims, nor is it intended to belimiting of the scope of the invention in any way.

It will be understood that the various embodiments of the presentinvention may include one, some, or all of the disclosed, described,and/or enumerated improvements and/or technical advantages and/orelements in claims to this invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A more particular description of embodiments of the invention brieflysummarized above may be had by references to the embodiments which areshown in the drawings which form a part of this specification. Thesedrawings illustrate certain preferred embodiments and are not to be usedto improperly limit the scope of the invention which may have otherequally effective or equivalent embodiments.

FIG. 1 is a schematic side view of a prior art shale shaker.

FIG. 2A is a schematic view of a system according to the presentinvention.

FIG. 2B is a schematic side view of shale shaker apparatus of the systemof FIG. 2A.

FIG. 3 is a side schematic view of a system according to the presentinvention.

FIG. 4 is a side schematic view of a system according to the presentinvention.

FIG. 5A is a schematic view of a prior art shale shaker.

FIG. 5B is a side schematic view of a system according to the presentinvention.

FIG. 6 is a side schematic view of a system according to the presentinvention.

FIG. 7 is a side schematic view of screen assemblies according to thepresent invention.

FIG. 8A is a side schematic view of a screen assembly according to thepresent invention.

FIG. 8B is an end view of a screen assembly of FIG. 8A.

FIG. 8C is an end view of a screen assembly of FIG. 8A.

FIG. 9 is an end view of a system according to the present invention.

FIG. 10A is a side view of a shale shaker according to the presentinvention.

FIG. 10B is a side cross-section view of the shaker of FIG. 10A.

FIG. 10C is a side cross-section view which shows the shaker of FIG. 10Awith its basket tilted.

FIG. 10D is a front end view of the shaker of FIG. 10A.

FIG. 10E is a schematic diagram of a control apparatus for the shaker ofFIG. 10A.

FIG. 10F is a top schematic view of a vibratory separator according tothe present invention.

FIG. 11A is a side end view of a shale shaker according to the presentinvention.

FIG. 11B is a partial cross-section view of the shale shaker of FIG.11A.

FIG. 11C is a partial cross-section view of the shale shaker of FIG.11A.

FIG. 11D is an end view of the shale shaker of FIG. 11A.

FIG. 12A is a side view of a rocker arm assembly of the shale shaker ofFIG. 11A.

FIG. 12B is a top view of the rocker arm assembly of FIG. 12A.

FIG. 13 is a schematic view of a control system according to the presentinvention for a vibratory separator according to the present invention.

FIG. 14 is a schematic view of a system according to the presentinvention.

FIG. 15 is a side view of a shale shaker according to the presentinvention.

FIG. 16 is a top view of the shale shaker of FIG. 15.

FIG. 17 is an end view of the shale shaker of FIG. 15.

FIG. 18 is an illustration of a preferred status display for an oilrecovery system showing status for individual rigs and aggregatedworst-case status for geographical areas.

FIG. 19 is an illustration of a preferred status display for an oilrecovery system showing status for individual rigs and aggregatedworst-case status for a smaller geographical area including WesternCanada.

FIG. 20 is an illustration of a preferred status display for an oilrecovery system showing status for individual rigs and panel resultsshowing text descriptions and color-coded status for a single oil rig.

FIG. 21A is an illustration of a preferred status display for an oilrecovery system and a sub status for an individual rig.

FIG. 21B is an illustration of an alternative status display for an oilrecovery system and a sub status for an individual rig.

FIG. 22 is an illustration of a preferred status display for an oilrecovery system and a lower level sub status for an individual rig.

FIG. 23 is an illustration of a preferred status display for an oilrecovery system and a lower level sub status for an individual rig.

FIG. 24 is an alternative tabular status display for an oil recoverysystem.

FIG. 25 is an alternative tabular status display for an oil recoverysystem.

FIG. 26 is an illustration of a preferred health check system reportinghealth checks from an oil rig to a user via satellite.

FIG. 27 is an illustration of a preferred health check system reportinghealth checks of multiple equipments, processes or systems from multipleoil rigs to a multiple users.

FIG. 28 is an illustration of a preferred protocol which defines anevent reporting data structure for data base population and display.

FIG. 29 is a screen display for a system according to the presentinvention.

FIG. 30 is a screen display for a system according to the presentinvention.

FIG. 31 is a screen display for a system according to the presentinvention.

FIG. 32A is a screen display for a system according to the presentinvention.

FIG. 32B is a screen display for a system according to the presentinvention.

Presently preferred embodiments of the invention are shown in theabove-identified figures and described in detail below. Various aspectsand features of embodiments of the invention are described below andsome are set out in the dependent claims. Any combination of aspectsand/or features described below or shown in the dependent claims can beused except where such aspects and/or features are mutually exclusive.It should be understood that the appended drawings and descriptionherein are of preferred embodiments and are not intended to limit theinvention or the appended claims. On the contrary, the intention is tocover all modifications, equivalents and alternatives falling within thespirit and scope of the invention as defined by the appended claims. Inshowing and describing the preferred embodiments, like or identicalreference numerals are used to identify common or similar elements. Thefigures are not necessarily to scale and certain features and certainviews of the figures may be shown exaggerated in scale or in schematicin the interest of clarity and conciseness.

As used herein and throughout all the various portions (and headings) ofthis patent, the terms “invention”, “present invention” and variationsthereof mean one or more embodiment, and are not intended to mean theclaimed invention of any particular appended claim(s) or all of theappended claims. Accordingly, the subject or topic of each suchreference is not automatically or necessarily part of, or required by,any particular claim(s) merely because of such reference. So long asthey are not mutually exclusive or contradictory any aspect or featureor combination of aspects or features of any embodiment disclosed hereinmay be used in any other embodiment disclosed herein.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to FIGS. 2A and 2B, a drilling system 10 according to thepresent invention includes a rotary bit 12 attached to the lower end ofa length of hollow drill pipe 14 suspended from a drilling derrick (notshown).

The drill pipe 14 and attached drill bit 12 are rotated to cut into thesubsurface formation 16 to form a wellbore 18. The drill pipe 14 passesthrough a wellhead assembly 20 located at the surface. The wellheadassembly 20 controls flow of drilling fluid into the well. During thedrilling of the well, a drilling fluid 22 commonly referred to asdrilling mud is pumped down the interior of the hollow drill pipe 14.The drilling mud exits jets such as jet 24 in drill bit 12 and impingesupon a bottom 26 of the well bore 18. The drilling fluid exiting thejets 24 flushes away from the bottom 26 of the wellbore 18 the cuttingsor particles generated as the drill bit 12 cuts into the earthenformation 16. A stream of drilling mud 22 then carries the cuttings andparticles upward through a well annulus 28 (arrows 29) to the wellhead20. The drilling mud 22 with the particles and cuttings carried orsuspended therein, exits the wellhead 20 at outlet 31 and passes througha conduit 30 to a shaker system according to the present invention whichincludes a shale shaker 32.

In the shaker 32, the drilling mud and particles are deposited upon oneor more screens which are vibrated so that the larger particles aresifted out of the drilling mud and carried off the top of the screen(s).

A liquid portion of the drilling mud along with very fine suspendedparticles exits a first shaker outlet 34 and is received in a mud pit36.

Larger particles 44 which are sifted out of the stream of drilling mudexit a second shaker outlet or trough 38 and are conveyed on a conveyoror slide 40 for deposit into a reserve pit 42 or into storage tanks forhaulage to another location. The drilling mud is pumped from the mud pit36 through a line 46 by a mud pump 50. The mud pump 50 then pumps themud through a discharge line 52 which returns it to the interior bore ofdrill pipe 14.

As shown in FIGS. 2A and 2B the shale shaker 32 has a fluid levelsensing apparatus 60 which is in communication with a control apparatus70. The sensing apparatus 60 senses a distance to a top surface of thedrilling mud 22 on a screen 33 of the shaker 32, which is indicative ofmud depth. Via a signal transmission line 62 (or multiple such lines ifneeded) the sensing apparatus sends a signal to the computer apparatus70 indicative of this distance. The apparatus 70 controls the sensingapparatus 60 via a line 63 (or multiple such lines if needed).

The shale shaker 32 (or a screen supporting basket thereof) is supportedby a first support 37 which has a pivotal connection 39 and by a secondsupport 51 which has a pivotal connection 52 and a movable post 53 whichis selectively movable up and down by moving apparatus 54 to pivot theshale shaker 32 (or its basket alone) on the pivotal connection 39 toaffect the angle of the shaker or basket 32, the depth of drilling fluidbeneath the sensing apparatus 60, and the extent of a beach area on thescreen 33. Via a line 65 the computer apparatus 70 controls a controlapparatus 72 that selectively operates the moving apparatus 54 (whichmay be pneumatically, hydraulically or electrically powered as may beany such apparatus or height adjustment apparatus of any systemaccording to the present invention).

The sensing apparatus 60 may be (and as may be the case for any sensorof any system disclosed herein) any suitable known level and/or distancesensing apparatus including, but not limited to, the following types:electrical, optical, electromagnetic, ultrasonic, acoustic, andpulse-echo, and may be like the level sensing systems disclosed in U.S.Pat. Nos. 6,691,025 B2; 5,793,705; 5,319,972; 6,484,088 B1; 6,062,070;and 5,131,271 (all said patents incorporated fully herein for allpurposes) and the systems referenced, referred to or mentioned in thesepatents. The apparatus 70 may be (and as may be for any system disclosedherein) any suitable computer, computers, computer system,microprocessor-based system and/or programmable logic controller(s).

FIG. 3 shows a shale shaker 100 according to the present invention whichhas a basket 101 vibrated by interconnected vibrating apparatus 107. Thebasket 101 supports three screens 102, 103, 104 for treating materialintroduced onto screen 104 from a tank 106. An ultrasonic level sensor110 is connected to the basket 101 and selectively senses the distanceto, and, therefore the level of the material 114 (e.g., drilling fluidwith solids entrained therein) at a location 116 above the screen 103. Acontrol apparatus 111 controls the sensor 110 via a cable 118 and also,via the cable 118, the sensor 110 sends signals to the control apparatus111 indicative of a measurement of the level at the location 116. In oneaspect the control apparatus 111 includes suitable apparatus (e.g. likethe apparatus 70 described above) which calculates the depth at thelocation 116 and, based on suitable programming in suitable programmingmedia in the control apparatus 111, adjusts the inclination of thebasket 101 using adjustment apparatus 112 so that the depth at thelocation 116 is maintained at a desired level.

In one aspect the basket 101 is pivotally connected to a support 113 ata pivot point 115. The support 113 is secured to a base 105, as is thetank 106 and adjustment apparatus 112. Fluid and/or solid materialflowing through the screens 102-104 flows down into a receptacle 117.Separated material 108 flows off an exit end of the last screen 102.

FIG. 4 shows a shale shaker 120 according to the present inventionsimilar to the shale shaker 100, FIG. 3 (and like numerals indicate likeparts); but the shale shaker 120 has individual tilting mechanisms 131,132, 133 (each with a respective pivot point 131 a, 132 a, 133 a) eachbeneath a respective screen 121, 122, 123. Levels of drilling fluid 128at various locations on the screens 121-123 can be adjusted byselectively changing the inclination of the screens 121-123. Controlapparatuses 134-136 correspond, respectively, to the mechanisms 131-133.A control system 127 with suitable control apparatus (e.g. like theapparatus 70, FIG. 2B) communicates with the control apparatuses 131-133and also with individual level sensors 124, 125, and 126. Each sensor124-126 senses the level of drilling fluid 128 at, respectively,locations 137, 138 and 139. The control apparatus in one aspect ispre-programmed to maintain the drilling fluid levels at locations137-139 at predetermined levels by monitoring the levels with thesensors 124-126 and adjusting the depths at those locations by pivotingthe screens 121-123 by pivoting the individual tilting mechanisms131-133. Any one or any two of the sensors 124-126 may be deleted andthe corresponding tilting mechanism(s) and associated control(s) may bedeleted.

FIG. 5A shows a prior art shale shaker with a pivot point at or near amid-point of a shaker basket (“fine screening basket”). FIG. 5B shows ashale shaker 150 according to the present invention which has a basketpivot point 161 at or near one end of a basket 160. The shaker 150 has aback tank 151 from which material to be treated flows into a scalpingbasket 170 which removes massive and/or gross size pieces and particlesand from which material then flows down onto screens 153-156. Heightadjustment apparatus 158 (controlled as is any adjustment apparatusdisclosed herein) selectively pivots the basket 160 about the point 161.Vibrating apparatus 157 vibrates the basket 160. Material passingthrough the screens flows into a receptacle 159 on a skid 165.

In one aspect the present invention provides a separator like thatdisclosed in U.S. Pat. No. 4,082,657 (incorporated fully herein for allpurposes); but with improvements according to the present invention. Asshown in FIG. 6 a separating device D according to the present inventionfor separating particulate from a fluid stream includes a frame 210having mounted thereon an inlet tank 211 for receiving a fluid to befiltered or cleaned. Screen units 214 a and 214 b are mounted incascaded alignment on the frame 210 by vibration mount means generallydesignated as 215 a and 215 b which each includes a vibrating means 216mounted therewith for vibrating screen units 214 a and 214 bsimultaneously.

The frame 210 includes first and second side members 210 a (only one isillustrated) which are connected together by a front end connecting rod210 b and a rear connecting rod 210 c. The front and rear connectingrods 210 b and 210 c cooperate with the side members such as 210 a toprovide a generally rectangular form having an opening therethroughthrough which the cleaned fluid stream may pass to a recovery areapositioned therebelow. The side frame members such as 210 a may beI-beams or other suitable frame members for supporting the structure tobe disclosed here.

The inlet tank 211 has connected therewith an inlet line 211 b forreceiving the fluids to be cleaned. In one aspect the screen unit 214 aand 214 b includes a metal frame with screening material thereon.

The screen units are releasably mounted in screen unit mounting assemblysupports 222 and 222 a.

Each screen unit is supported by four adjustable posts 235 (two shown oneach side of each screen; e.g. as described in U.S. Pat. No. 4,082,657).Optionally, interposed between the screen units' supports 222, 222 a arespring mechanisms 233 and 234. Vibratory apparatuses 216 vibrate thescreen units.

A sensor 240 on a support 240 a senses the depth of fluid on the screenunit 214 a and a sensor 242 on a support 242 a senses the depth of fluidon the screen unit 214 b. A control apparatus 250 (like any disclosedherein) is in signal communication with the sensors 240, 242 via cables243, 244. The control apparatus 250 is also in communication via cables247, 248 with control apparatuses 245, 246 which control theheight-adjustable posts 235. The control apparatuses 250, 245, 246 maybe like any control apparatus and/or computer apparatus described above.

FIG. 7 shows three screen assemblies 261, 262, 263 according to thepresent invention which may be used in any system according to thepresent invention in which screen assemblies, screens, or individualscreen supports are tilted or moved to adjust fluid depth at a locationon a screen assembly or screen. Each screen assembly 261-263 has anexpandable member 264 (e.g., but not limited to, an expandable bellowsor seal) which insures that sealing contact is maintained betweenadjacent screen assemblies (or between a screen assembly end and amember on a basket against which a screen assembly end abuts). In oneaspect as shown the expandable members 264 are bellows seals; but it iswithin the scope of this invention for any suitable seal or sealingmaterial to be used which can expand and contract sufficiently tomaintain a seal between adjacent screens.

FIGS. 8A-8C illustrate a screen assembly 265 according to the presentinvention which has a flexible end seal 266 which seals against an endof an adjacent screen 267. The seal 266 is sufficiently wide that itwill seal against the end of the screen assembly 267 when theinclination of the screen assembly 267 is changed (and/or when theinclination of the screen assembly 265 is changed (e.g. in response to asignal from a fluid level sensor above either or both screen assemblies265, 267. Optionally, the screen assembly 267 may also have an end seal264.

FIG. 9 shows a vibratory separator 270 according to the presentinvention with walls 274 and a screen assembly 271 in a crownedconfiguration with fluid 272 to be treated thereon. A fluid level sensor273 connected to a wall 274 of the separator 270 with a connector 275senses fluid level near a center point of the screen assembly 271 (asviewed in FIG. 9). A fluid level sensor 276 senses fluid level near thewall 274. It is within the scope of the present invention to locate oneor more fluid sensors at any point above a screen assembly in avibratory separator or shaker. Optionally, either sensor 273 or 276 maybe deleted.

FIGS. 10A-10D show a shale shaker 300 according to the present inventionwhich is like a King Cobra Shale Shaker commercially available fromVarco International, Inc., but which has improvements according to thepresent invention. The shale shaker 300 has a skid or base 302 on whichis a basket 306 which is vibrated by vibration apparatus 304. From aweir tank 308 fluid, e.g. drilling fluid with drilled cuttings anddebris therein, flows onto a first screen 310 which is supported by ascreen support 310 a connected to the basket 306. Part of the fluid thenflows onto a second screen 311 supported by a screen support 311 aconnected to the basket 306 and then part of the fluid flows onto a lastscreen 312 supported by a screen support 312 a connected to the basket306. Part of the fluid flows off an exit end 312 b of the screen 312onto an optional lower screen 313 which is supported by a screen support313 a connected to the basket 306.

The fluid forms a pool 315 above the screens 310-312. Depending on thefluid, on the fluid viscosity, on the fluid's solids content, on therate of fluid flow, and the through-put of the screens, a beach 316 iscreated at the exit end 312 b of the screen 312. It is desirable tooptimize the extent of this beach 316 and, in certain aspects, it ispreferred that the beach, as viewed in FIG. 10B, be sufficiently largethat no fluid flows untreated off the last screen 312.

An ultrasonic transducer sensor measurement apparatus 320 is connectedto the basket 306 (e.g. to a motor tube 309 and/or such a sensorapparatus 320 b is connected to a weir tank 308) and is, optionally,positioned above the pool 315, e.g. over an entry end 310 b of thescreen 310 or over an entry end 312 c of the screen 312. Such locationsfor the apparatus 320 provide measurement at locations providing thegreatest range of pool depth and therefore, the greatest range foradjusting beach extent; i.e., such a location insures that theapparatuses 320 a and/or 320 b will have a sensor-to-pool-surfacedistance to measure since in most cases there will be fluid at somedepth at this point beneath the apparatus or apparatuses 320. Theapparatuses 320 a and/or 320 b are in communication with a controlapparatus 330. The sensor apparatuses generates a signal indicative ofsensor-to-pool distance which indicates depth of the pool 315 beneaththe sensor apparatus(es). Optionally, either the sensor 320 a or thesensor 320 b is deleted.

The control apparatus 330 (e.g. a computer, PLC, PID controller, orother device with programmable media) selectively controls a controlvalve 336 which allows hydraulic fluid under pressure from a reservoir338 pumped by an hydraulic pump 337 to move to and from two hydrauliccylinder apparatuses (one shown, FIG. 10A) which are on opposite sidesof the shaker 300. A flow control valve 332 controls the flow of fluidinto/out of the pistons and adjusts the rate of stroke in the cylinderapparatuses 333, 334 and a flow control valve 335 limits the flow offluid to/from the pistons and adjusts the rate of stroke out of thecylinder apparatuses 333, 334. An hydraulic cylinder apparatus 350 hasan extendable piston 351 pivotably connected to a pivot plate 353 at apivot point 365. The plate 353 is pivotably connected at a pivot point357 to the basket 306. A housing 350 of the apparatus 334 is secured toa mount 359 which is pivotably connected to the basket 306. A link 355is pivotably connected to the plate 353 at a pivot point 366 and thelink 355 is connected to a link 356 that is pivotably connected at apivot point 354 to a basket support 340. The basket support 340 issupported by the hydraulic cylinder apparatuses and by bases 341. Shafts367 of the basket supports 340 are pivotably mounted on the bases 341. Ascale 339 indicates the angle of the support 340 with respect tohorizontal (i.e. assuming the skid or base 302 is level). The support340 is connected to springs 346, 343 which support basket mounts 345 and342, respectively; and similar springs and mounts are on the other sideof the basket.

In another aspect the plate 365 is deleted and the hydraulic cylinderapparatuses are oriented almost vertically and the hydraulic cylinderapparatuses' pistons 351 are pivotally connected to the basket support340 for selectively raising and lowering it to adjust beach extent.

FIG. 10C shows the basket 306 tilted as compared to the basket 306 asshown in FIG. 10A.

In one aspect a vibratory separator or shale shaker according to thepresent invention may employ a material flow sensor which produces asignal indicative of the presence or absence of material flowing ontoscreen apparatus; e.g., but not limited to, drilling fluid with drilledsolids flowing onto screen apparatus of a shale shaker. Such anindication is valuable in insuring that, upon flow commencing againfollowing cessation of material flow which is common when drilling isstopped, a screen or a basket is not inclined at such an angle that arelatively low depth pool is formed resulting in the loss of untreateddrilling fluid flowing off a screen exit end. By adjusting screen orbasket angle so that flow recommencement is accommodated, a pool isformed of sufficient depth and extent that all or the great majority ofmaterial is treated and an optional amount of drilling fluid flowsthrough the screen and is recovered.

Optionally, a shaker 300 as shown in FIGS. 10A and 10B (with or withouta sensor or sensors like the sensor 320 a and/or 320 b) has a materialflow switch device 307 connected to vibratory separator adjacent amaterial input tank like the tank 308 for sensing when material isflowing. The device 307 may be any suitable known flow sensor apparatus,including, but not limited to paddle switch systems, including, but notlimited to, FS-550 Series paddle switches from Gems Sensors Co.

The device 307 is in communication with and controlled by the controller330 and, in one aspect, signals from the device 307 override signalsfrom sensors like the sensors 320 a and 320 b so that the controller 330knows that material flow has ceased (rather than an indication from thesensors 320 a, 320 b that the pool is very shallow). In response tosignals from the device 307 the controller 330 can activate theapparatus for adjusting basket angle.

Once material flow into the basket is again proceeding, the controller330 (acting upon signals from the sensor 320 a and/or the sensor 320 b)adjusts the basket angle to maintain the desired beach extent. Althoughone particular flow sensor has been mentioned, it is to be understoodthat any suitable known flow sensor device or system may be used,including, but not limited to, ultrasonic transducer systems.

The controller 330 may be any suitable known commercially availablecontroller apparatus, including, but not limited to computerizedsystems, digital signal processor systems, programmable logic controllersystems, and/or microprocessor systems. One suitable sensor apparatusand associated control system is the model XPS-10 and Hydro Ranger 200from Siemens.

FIG. 10F shows schematically a vibratory separator or shake shaker 400according to the present invention which has a screen-supporting basket402 with pivot members 414 pivotally mounted on supports 404 on a skidor base 406. Adjustment apparatuses 408, 410 on either side of thebasket 402 (like any adjustment apparatus described herein) raise andlower an end 412 of the basket 402, pivoting it about the pivot members414. In one aspect a rear line 416 of a beach area 420 of a screen 430supported in the basket 402 coincides with a line between the pivotmembers 414.

A sensor 418 (like any sensor disclosed herein, including but notlimited to those in FIGS. 1-10A) is positioned above a fluid entry endof the screen 430 on a connecting member 422 connected to the basket402. A sensor 451 (like any sensor herein) is positioned above a fluidentry end of the screen 434 and may be conveniently connected to a baror beam which is connected to the tank 450 and/or to the basket 402.Material flows from a screen 432 to the screen 430 and from a screen 434to the screen 432. Any suitable tank 452 and/or fluid introductionapparatus may be used. Vibrating apparatus 440 vibrates the basket 402.

A power apparatus 441 connected to the shaker 400 powers the adjustmentapparatuses 408, 410 and may be located at any suitable location on theshaker 400 including, but not limited to, on the basket 402 or on theskid 406. Optionally the power apparatus 441 is any such apparatus orsystem disclosed herein. In one aspect the power apparatus 441 includesan hydraulic pump in fluid communication with an hydraulic fluidreservoir 440 via a line 444 and the apparatuses 408, 410 arehydraulically-powered apparatus in fluid communication with the pump vialines 442, 443. Control apparatus 450 (as any disclosed herein) controlsthe apparatus 441, the sensor 418, a sensor 460, a controller 456,and/or the sensor 451. Optionally, a material flow sensor 460 connectedto the tank 452 (or at any suitable location in the separator 400) whichis like the sensor 307, FIG. 10A, senses the presence or absence ofmaterial flowing from the tank 452 onto the screen 434. The sensor 460is in communication with the control apparatus 450 and, in response tosignals from the sensor 460, the control apparatus 450 adjusts thebasket angle to accommodate material flow and to adjust forrecommencement of flow following flow cessation. Optionally, a flow ratecontroller 456 controls the amount of fluid introduced onto the screen434 from the weir tank 452 and a control switch 455 of the controller456 is in communication with the control apparatus 450.

It is within the scope of this invention for the apparatuses 408, 410 tobe located at any desirable effective location with respect to thebasket, as may be the case with any adjustment apparatus disclosedherein.

The present invention, therefore, in some and not necessarily allembodiments, provides a vibratory separator having a screen support orbasket for supporting screen apparatus for treating material introducedinto the vibratory separator, the basket on a base and pivotable withrespect thereto, vibratory apparatus connected to the basket forvibrating the basket, screen apparatus supported by the basket, thematerial forming a pool on the screen apparatus, and a beach on thescreen apparatus adjacent the pool, measurement sensor apparatusconnected to the vibratory separator and positioned above the screenapparatus for measuring a distance from the measurement sensor apparatusto a top surface of the pool, the measurement sensor apparatus includinga signal production portion for producing signals indicative of saiddistance and for transmitting said signals, a control system forcontrolling and in communication with the measurement sensor apparatusfor receiving signals from the measurement sensor apparatus indicativeof said distance and for processing said signals to calculate a pooldepth corresponding to said distance, and angle adjustment apparatusconnected to the basket and controlled by the control system foradjusting angle of the basket, thereby adjusting extent of the beach.Such a vibratory separator may have one or some, in any possiblecombination, of the following: wherein the vibratory separator is ashale shaker and the material is drilling fluid with drilled cuttingstherein; wherein the screen apparatus includes at least an exit screenwith an exit end from which material separated by the screen apparatusflows off the screen apparatus for discharge from the vibratoryseparator, wherein the basket is at an angle such that the beach isformed adjacent an edge of the pool adjacent said exit end, and whereinthe control system controls extent of the beach; wherein the controlsystem controls extent of the beach to maintain the beach on the exitscreen; wherein the screen apparatus is a plurality of screens placedadjacent each other in the basket, each screen with an associated screensupport connected to the basket; wherein the angle adjustment apparatusincludes a basket support pivotably mounted to the base and movingapparatus for selectively moving the basket up and down; wherein thebasket has a fluid entry end and a fluid exit end and wherein the basketis pivotably mounted adjacent the fluid exit end, and wherein the angleadjustment apparatus moves the basket's fluid entry end; wherein themoving apparatus includes hydraulic cylinder apparatus for moving thebasket; wherein the hydraulic cylinder apparatus includes twohydraulically powered piston apparatuses, each on a side of the basketfor moving the basket; wherein each hydraulically powered pistonapparatus is pivotably interconnected with corresponding linkageapparatus, the linkage apparatus pivotably connected to the basketsupport adjacent the fluid entry end of the basket; wherein themeasurement sensor apparatus is ultrasonic apparatus; wherein theultrasonic apparatus is at least one ultrasonic apparatus; wherein themeasurement sensor apparatus is a plurality of distance sensorapparatuses; wherein the plurality of sensor apparatuses includes afirst ultrasonic sensor apparatus spaced-apart from a second ultrasonicsensor apparatus, the first ultrasonic sensor apparatus above one sideof the screen apparatus and the second ultrasonic sensor apparatus abovean opposite side of the screen apparatus; wherein the measurement sensorapparatus is from the group consisting of electrical, optical,electromagnetic, ultrasonic, acoustic, and pulse-echo apparatus; whereina rear boundary of the beach is along a rear beach line and the basketis pivotably connected to the base beneath the rear beach line; and/orwherein the angle adjustment apparatus is powered by power apparatus.

FIGS. 11A-11D show a shale shaker 500 according to the present inventionwhich is like a King Cobra Shale Shaker commercially available fromVarco International, Inc., but which has improvements according to thepresent invention. The shale shaker 500 has a skid or base 502 on whichis a basket 506 which is vibrated by vibration apparatus 504. From atank 508 fluid, e.g. drilling fluid with drilled cuttings and debristherein, flows onto a first screen 510 which is supported by a screensupport 510 a connected to the basket 506. Part of the fluid then flowsonto a second screen 511 supported by a screen support 511 a connectedto the basket 506 and then part of the fluid flows onto a last screen512 supported by a screen support 512 a connected to the basket 506.Part of the fluid flows off an exit end 512 b of the screen 512 onto anoptional lower screen 513 which is supported by a screen support 513 aconnected to the basket 506. Fluid flows into a lower sump or receptacle503.

The fluid forms a pool 515 above the screens 510-512. A beach 516 is atthe exit end 512 b of the screen 512. It is desirable to control and/oroptimize the extent of this beach 516 and, in certain aspects, it ispreferred that the beach, as viewed in FIG. 11B, be sufficiently largethat no fluid flows untreated off the last screen 512.

An ultrasonic transducer sensor measurement apparatus 520 is connectedto the shale shaker, e.g. to a skid, base, tank or as shown to thebasket 506 and is, optionally, positioned above the pool 515, e.g. overan entry end 510 b of the screen 510. The apparatus 520 is incommunication with a control apparatus 530 (e.g., but not limited to, acomputer). The sensor apparatus generates a signal indicative ofsensor-to-pool distance which indicates depth of the pool 515 beneaththe sensor apparatus(es).

The control apparatus 530 selectively controls a bladder apparatus 536which selectively raises and lowers a rocker arm assembly 540 which, inturn, raises and lowers the basket 506 to which the rocker arm assembly540 is connected. Optionally the rocker arm assembly's angle withrespect to the horizontal is selectively adjustable by a mechanicalmechanism, e.g. any suitable known mechanical mechanism for moving therocker arm assembly up and down, e.g., but not limited to, a screwmechanism or an hydraulic or pneumatic piston device.

A top part 536 a of the bladder apparatus 536 contacts a lower surface541 a of a plate 541 of the rocker arm assembly 540. The bladderapparatus 536 inflates to raise the rocker arm assembly 540 and deflatesto lower it. A gas, e.g. air, or a liquid, e.g. a water-glycol mixture,can be used to inflate the bladder apparatus 536. The control apparatus530 controls the bladder apparatus 536. It is within the scope of thepresent invention to use, instead of the air bladder apparatus 536, tomove the rocker arm assembly up and down: a linear actuator device orother electronically-operated device; a hydraulically-powered device,e.g. an hydraulic cylinder system; or an air-over-hydraulic apparatus,e.g. a system with a liquid-filled tank with air pressure. In oneparticular embodiment the air bladder apparatus 536 is a commerciallyavailable Model 20-2 from Firestone Company. Although only one airbladder apparatus 536 is shown, it is within the scope of the presentinvention to use two such apparatuses, one on each side of the basket506.

The rocker arm assembly 540 has pivot shafts 542 which pivot incorresponding recesses 543 of mounts 544 on the skid 502. The rocker armassembly 540 has two side members 545 interconnected with an end member546. Spring mounts 54, welded to the basket 506, support springs 548which are connected to the brackets 549.

An optional ultrasonic sensor apparatus 522, in communication with thecontrol apparatus 530, senses whether or not there is fluid flow fromthe tank 508 to the pool 515. If a “no-flow” signal is generated by theapparatus 522 and sent to the control apparatus 530, then the basket istilted to its maximum uphill angle in anticipation of a next rush ofmud. An optional ultrasonic sensor apparatus 524 senses the location(height) of the plate 541, and produces a signal indicative of thislocation, which is a signal whose value corresponds to the angle of therocker arm assembly 540 and, therefore, to the angle of the basket 506(and which correlates with signal values from the apparatus 522). In oneaspect, the control apparatus 530 computes the basket angle based on thesignal from the ultrasonic sensor apparatus 524 and correlates thiscomputed angle with the value for the pool depth based on the signalfrom the ultrasonic sensor apparatus 520. If these two values correlate,this indicates the system is working properly. If there is a discrepancybetween the values (from the ultrasonic sensors) (e.g. a discrepancycaused by high flow, downhill basket orientation or low fluid level)this indicates a measurement problem and the control apparatus 530 thenadjusts the basket to a fully uphill angle until there is no suchdiscrepancy.

Optionally, the shale shaker 500 includes a variable frequency drive 550(optionally in an enclosure rated for a Class 1, Division 1, or Zone 1hazardous area) whose functions include varying the rpm's of thevibration apparatus 504 and thus varying the G-forces (acceleration)imparted to the basket 506 by the vibration apparatus 504; and changingthe direction of rotation of the vibration apparatus 504 therebychanging the motion of the basket 506, e.g. from linear motion toelliptical motion. In one particular aspect the vibration apparatus 504includes a Model VMX 18-8300-80 vibrator or a Model VMX 18-8300-110 fromMartin Engineering which have dual motion motors with the capability ofchanging an imbalance of weights based on rotation direction to changemotion, e.g. from linear to elliptical (or vice versa). The controlapparatus 530, and/or the ultrasonic sensor apparatus 524 and/or theapparatus 550 may be located at any convenient location on the shaleshaker 500. As shown in FIG. 11A they are protected within an enclosure554 formed of parts of the tank made of resilient material, e.g. metalor composite. Alternatively the drive 550 is located in a separateenclosure 554 a (shown by dotted lines).

Apparatus 552 provides a channel 553 for fluid in the tank 508 to bypassthe screens 510-512 and flow directly into the receptacle 503.

FIG. 13 shows a computer 560 which can be used, in one aspect, for thecontrol apparatus 530. Optionally, the computer 560 is positioned withinan enclosure 561 which is suitable for installation in a Class 1,Division 1 or Zone 1, hazardous area. AC Power is input to an AC to DCtransformer 562 which provides power to a power supply 579 and to apower supply 563 (which in turn supplies power to barrier devices 564,565, and 566). The power supply 563 provides power, e.g. 24 VDC, to apower supply 567 of an Input/Output device 568. The power supply 579provides power (e.g. 5 VDC) to a single board computer 569 which runs acontrol program and reads the I/O device, and sends control signals toelectrically actuated valves (e.g. 670, 671, FIG. 14) to control theshaker's basket angle. The power barrier devices 564-566 provide power,e.g. 24 VDC, to various intrinsically safe (“IS”) devices, e.g. theultrasonic sensor apparatuses. The computer 569 can be programmed toprovide a basket angle reset to reset a value of the ultrasonic sensorapparatuses' measurement of a “home” position of the basket (e.g. amaximum uphill angle).

Analog barrier devices 571 and 572 limit the power of signals on analogdevices, i.e. the ultrasonic sensors. Supply 567 provides power to thedevices 573-576. A digital input card 573 receives digital input signalsfrom other devices, e.g. the VFD and user push buttons. A digital outputcard 574 outputs digital signals to other devices, e.g. to the VFD. Arelay card 575 provides switch openings and closures for sending controlsignals from the computer to other devices, e.g. control valves. Ananalog input card 576 receives analog signals from other devices; e.g.from the ultrasonic sensor apparatuses.

Optionally the Input/Output device 568 may have a switch or connection578 for communication with a system (e.g. a computer or computer system)apart from and/or remote from a shale shaker or vibratory separator,e.g., but not limited to an Ethernet Input/Output Controller which, inturn, provides to connection to other systems, e.g. the Internet.

FIG. 14 illustrates schematically a system 600 according to the presentinvention which is like the systems shown in FIGS. 11A-13. A shaker 601(e.g. like the shaker 500 or any shaker disclosed or referred to herein)has a rocker arm assembly 640 (e.g. like the assembly 540) which can beraised and lowered by a bladder apparatus 636 (e.g. like the apparatus536) which is mounted on a skid 602. Vibratory motors 604 (e.g. like themotors 504) vibrate a basket 606 (e.g. like the basket 506).

Ultrasonic sensor apparatuses 620, 622, 624 (e.g. like the apparatuses520, 522 524) provide signals to a control system 630 (e.g. like thecontrol apparatus 530) for sensing system parameters and for controllingthe rocker arm assembly to adjust basket angle and to control the motors604. The control apparatus 630 is housed within an enclosure 654 (e.g.like the enclosure 554).

An optional variable frequency drive system (“VFD”) 650 (e.g. like thesystem 550) in an enclosure 654 a (e.g. like the enclosure 554 a) is incommunication with the system 630 and provides control of the motors 604(i.e. control of G forces on the screens and/or control of type ofmotion) and control of the basket angle. In one particular aspect thesystem 630 has manually-operable push buttons 631-634. The buttons631-633 provide for calibration of the ultrasonic sensor apparatuses620, 622, 624, respectively. The button 634 is a system re-set button.In one aspect the buttons are tied to a digital input card in theenclosure.

The VFD 650 has manually-operable push buttons 651-656 and 658-659 whichfunction as follows:

-   -   651 On    -   652 Off    -   653 Switch between linear/elliptical motor motion    -   654 Power to system 630    -   655 Switch between automatic and manual mode    -   656 System 650 re-set    -   658 Move basket up (increase basket angle)    -   659 Move basket down (decrease basket angle)

Valves 670 and 671 are electronically-operated valves. Power is providedto the valve 670 via a power line 681 from the system 630 and to thevalve 671 via a power line 684. The basket is raised or lowered byselectively opening or closing the valve 670 which permits fluid 692(e.g. a water-glycol mixture) to flow to or from the bladder apparatus636 from a controlled pressure reservoir 691 in a line 675 and to orfrom the valve 670 in a line 677.

The valve 671 controls air flow between an air inlet 672 and thereservoir 691. Air under pressure from a source 692 flows in a line 693to the air inlet 672 and then via the lines 678 and 674 to and from thereservoir 691 to move the fluid 692 for raising and lowering of thebasket to adjust basket angle.

A cooler 673, e.g. a vortex cooler apparatus in fluid communication withthe air inlet 672 via lines 678 and 685, cools the interior of theenclosure 654 a.

FIGS. 15-17 show a shale shaker 70 according to the present inventionwhich has a screen-mounting basket 72 and a bridge 74 on which aremounted two vibrating apparatuses 75. The basket 72 has brackets 76 towhich are secured helical springs 77.

Each spring 77 is secured to a base member 77 a. As shown in FIG. 17, anoptional housing 79 may be used on sides of and beneath the shale shaker70. Optionally (and as may be the case with any shale shaker disclosedherein according to the present invention or with any known prior artshaker or vibratory separator) an electronic tracking apparatus 71 is onthe housing 79, but may, according to the present invention, be withinany suitable member or part of a shale shaker; and, optionally, such atracking apparatus has a container or housing made of composite materialand/or is encased within or coated with composite material. Any knowntracking device, apparatus, or system may be used, including, but notlimited to known satellite tracking systems.

The present invention, therefore, provides, in at least certainembodiments, a vibratory separator or shale shaker with a base; a basketmovably mounted on the base and for supporting screen apparatus fortreating material introduced into the vibratory separator, the basket onthe base and pivotable with respect thereto; vibratory apparatusconnected to the basket for vibrating the basket; screen apparatussupported by the basket, the material flowing onto the screen apparatusfor treatment; angle adjustment apparatus connected to the basket foradjusting angle of the basket; sensor apparatus, e.g., ultrasonic, forsensing a parameter indicative of basket angle and for providing asignal corresponding to said basket angle; control apparatus forreceiving signals from the sensor apparatus and for controlling basketangle based on said signals; the angle adjustment apparatus including arocker arm assembly with a first end and a second end, the first endpivotably mounted to the base adjacent and beneath a material input areaof the vibratory separator and the second end adjacent and beneath amaterial exit end of the vibratory separator; and the angle adjustmentapparatus including movement apparatus with a part thereof in contactwith the second end of the rocker arm assembly for moving the second endup and down to change basket angle, the movement apparatus controlled bythe control apparatus. Such an apparatus may have one or some, in anypossible combination, of the following: wherein the vibratory separatoris a shale shaker and the material is drilling fluid with drilledcuttings therein; wherein the vibratory apparatus comprises two motorsfor vibrating the basket, the two motors providing dual motioncapability; wherein the screen apparatus includes at least an exitscreen with an exit end from which material separated by the screenapparatus flows off the screen apparatus for discharge from thevibratory separator, wherein the basket is at an angle such that a beachis formed adjacent an edge of a pool of material adjacent said exit end,and wherein the control system controls extent of a beach; wherein thesensor apparatus is ultrasonic sensor apparatus; wherein the ultrasonicsensor apparatus is at least one ultrasonic sensor apparatus; whereinthe sensor apparatus is a plurality of sensor apparatuses; wherein saidplurality of sensor apparatuses includes a first ultrasonic sensorapparatus spaced-apart from a second ultrasonic sensor apparatus, thefirst ultrasonic sensor apparatus for sensing material level in thebasket and the second ultrasonic sensor apparatus for sensing rate ofmaterial flow into the basket; wherein the measurement sensor apparatusis from the group consisting of electrical, optical, electromagnetic,ultrasonic, acoustic, and pulse-echo apparatus; flow sensor apparatusconnected to the vibratory separator for sensing the flow of materialonto the screen apparatus, the flow sensor apparatus controlled by andin communication with the control apparatus, and the control apparatusfor adjusting basket angle in response to signals from the flow sensorapparatus; wherein said plurality includes a third ultrasonic sensorapparatus for sensing basket angle; wherein the angle adjustmentapparatus is powered by power apparatus from the group consisting ofpneumatic power apparatuses, hydraulic power apparatuses and electricpower apparatuses; and/or wherein the movement apparatus of the angleadjustment apparatus includes inflatable bladder apparatus which isselectively inflatable to raise and lower the rocker arm assembly.

The present invention, therefore, provides, in at least certainembodiments, a vibratory separator or shale shaker with a base; a basketmovably mounted on the base and for supporting screen apparatus fortreating material introduced into the vibratory separator, the basket onthe base and pivotable with respect thereto; vibratory apparatusconnected to the basket for vibrating the basket; screen apparatussupported by the basket, the material flowing onto the screen apparatusfor treatment; angle adjustment apparatus connected to the basket foradjusting angle of the basket; sensor apparatus connected to the basketfor sensing a parameter indicative of basket angle and for providing asignal corresponding to said basket angle; control apparatus forreceiving signals from the sensor apparatus and for controlling basketangle based on said signals; the angle adjustment apparatus including arocker arm assembly with a first end and a second end, the first endpivotably mounted to the base adjacent and beneath a material input areaof the vibratory separator and the second adjacent and beneath amaterial exit end of the vibratory separator; the angle adjustmentapparatus including movement apparatus with a part thereof in contactwith the second end of the rocker arm assembly for moving the second endup and down to change basket angle, the movement apparatus controlled bythe control apparatus; wherein the vibratory separator in one aspect isa shale shaker and the material is drilling fluid with drilled cuttingstherein; wherein the vibratory apparatus has two motors for vibratingthe basket, the two motors providing a dual motion capability; whereinthe screen apparatus includes at least an exit screen with an exit endfrom which material separated by the screen apparatus flows off thescreen apparatus for discharge from the vibratory separator; wherein thebasket is at an angle such that a beach is formed adjacent an edge of apool of material adjacent said exit end; wherein the control systemcontrols extent of a beach; wherein the sensor apparatus is ultrasonicsensor apparatus; wherein the sensor apparatus is a plurality of sensorapparatuses which includes a first ultrasonic sensor apparatus, secondultrasonic sensor apparatus, and third ultrasonic sensor apparatus forsensing basket angle, the first ultrasonic sensor apparatus for sensingmaterial level in the basket and the second ultrasonic sensor apparatusfor sensing material flow rate into the basket; the control apparatusfor adjusting basket angle in response to signals from the sensorapparatuses; and correlation apparatus for correlating signals from thethree ultrasonic sensor apparatuses to check system adjustment.

The present invention, therefore, provides, in at least certainembodiments, a vibratory separator with a base; a basket movably mountedon the base and for supporting screen apparatus for treating materialintroduced at a first end of the basket into the vibratory separator,the basket on the base and the first end pivotable with respect thereto,the basket having a second end spaced apart from the first end, materialexiting the basket at the second end; vibratory apparatus connected tothe basket for vibrating the basket; screen apparatus supported by thebasket, the material flowing onto the screen apparatus for treatment;angle adjustment apparatus connected to the basket for adjusting angleof the basket by pivoting the basket's first end; sensor apparatus forsensing a parameter indicative of basket angle and for providing asignal corresponding to said basket angle; control apparatus forreceiving signals from the sensor apparatus and for controlling basketangle based on said signals; and the angle adjustment apparatusincluding movement apparatus for moving the second end up and down tochange basket angle, the movement apparatus controlled by the controlapparatus.

Such an apparatus may have one or some, in any possible combination, ofthe following: wherein the vibratory separator is a shale shaker and thematerial to be treated is drilling fluid with drilled cuttings therein;wherein said plurality of sensor apparatuses includes a first ultrasonicsensor apparatus spaced-apart from a second ultrasonic sensor apparatus,the first ultrasonic sensor apparatus for sensing material level in thebasket and the second ultrasonic sensor apparatus for sensing rate ofmaterial flow into the basket and wherein said plurality of sensorapparatuses includes a third ultrasonic sensor apparatus for sensingbasket angle, and correlation apparatus for correlating signals from allthree ultrasonic sensor apparatuses to check system adjustment; avariable frequency drive connected to the basket for controlling thevibratory apparatus; computer apparatus for controlling the vibratoryseparator; wherein the computer apparatus performs the functions of avariable frequency drive; and/or boost push button apparatus formanually changing forces applied by the vibratory apparatus.

The present invention, therefore, provides, in at least certainembodiments, a method for treating material introduced to a vibratoryseparator, the method including introducing material to a vibratoryseparator, the vibratory separator like any according to the presentinvention, treating the material in the vibratory separator, andadjusting the angle of the basket with angle adjustment apparatus. Suchan apparatus may have one or some, in any possible combination, of thefollowing: wherein the vibratory separator is a shale shaker and thematerial is drilling fluid with drilled cuttings therein; and whereinthe vibratory apparatus comprises two motors for vibrating the basket,the two motors providing dual motion capability, the method furtherincluding changing motion using the two motors.

The present invention, therefore, provides, in at least certainembodiments, beach adjustment apparatus for adjusting extent of a beachon a screen of a vibratory separator, the screen mounted to a vibratablebasket of the vibratory separator, the beach adjustment apparatusincluding an end-pivotable basket support for supporting the basket, theend-pivotable basket support pivotable at a pivot end thereof, the endpivotable basket support having a second end spaced-apart from the pivotend, the second end positionable near an exit end of a vibratoryseparator; apparatus for pivoting the end-pivotable basket support atits pivot end; and the apparatus for pivoting the end-pivotable basketsupport including movement apparatus having a part thereof forcontacting the second end of the end-pivotable basket support forfacilitating pivoting movement of the end-pivotable basket support toraise and lower the second end to adjust the extent of the beach.

In certain aspects an automatic boost minimizes fluid loss over the endof a shaker during a flooding situation. Several standard prior artshakers operate with a fixed shaking force and frequency, and a manuallyadjustable basket angle and vibrate with a nominal acceleration(g-force) that is measured without drilling fluid. The addition ofdrilling fluid adds mass to the system, which decreases the systemacceleration. In addition, the angle of the basket is often manuallyadjusted according to the fluid level. Adjusting the basket angle keepsthe fluid extent (beach) at a desired point, e.g. in triple screenshakers at about the end of a third screen. However, when fluid flowrates change frequently in the field, the basket angle is often notadjusted to its optimum position. If the basket angle is left in thefully uphill position, several screens may be running dry, which candecrease screen life. If the basket angle is left in a downhill positionfor correct beach length, whole mud can be lost over the end of theshaker when flow rates increase.

In certain embodiments, a shaker according to the present inventionautomatically adjusts the basket angle according to the fluid level.Thus, the basket is tilted downhill when there is little flow cominginto the shaker. When the flow increases, the basket is automaticallytilted uphill to keep the beach at approximately the same position. Ifthe basket has been tilted fully uphill, and the fluid level ismeasuring high for a certain period of time (programmable into theshaker computer and/or controller), then the computer automaticallysignals the VFD (variable frequency drive, or inverter) to drive themotors faster, referred to as an “automatic boost” feature. Increasingthe motor speed increases the force applied to the basket and fluidsystem. This in turn increases the basket acceleration, which increasesthe flow capacity of the shaker. Thus, this automatic boost featurehelps prevent a shaker from flooding and losing whole mud.

Many traditional prior art shakers operate with a fixed motion profile.These motion profiles are either linear, elliptical, or circular. Eachmotion tends to be best suited for a particular mud condition. Forinstance, circular motion can perform well with sticky clays, linearmotion performs well in high flow conditions, and elliptical motion canoffer a compromise between linear and circular. Some current prior artshakers can manually switch motion profiles between linear andelliptical. These shakers include the Brandt King Cobra +, Brandt KingCobra II, and Swaco Mongoose. Certain shakers according to the presentinvention may have a custom shaker motion profile which is ellipticalwith varying aspect ratio. A motion profile is the motion shape atdifferent points on the shaker, a motion imparted to material moving onthe shaker. For example, overall shaker performance can, in certainaspects, be improved by having a different motion shape at the dischargeend of a shaker than at the feed end or in the middle of a shaker. Inone aspect, the tuned motion in the feed end of the shaker is a thinellipse (approximately 5% aspect ratio), which can appear to be linear;the tuned motion near the center of the basket is a medium shapedellipse (approximately 15% aspect ratio); and the tuned motion near thedischarge end of the shaker is a fatter ellipse (approximately 30%aspect ratio). The acceleration level and angle of attack remainreasonably consistent and uniform front to back. In one aspect, thismotion profile enhances performance in drilling mud with sticky clays.With this configuration, the conductance is increased (fasterelimination of liquid from the mud) with the thin ellipse at the feedend of the shaker. The conveyance is enhanced at the discharge end ofthe shaker by the more pronounced elliptical motion. The more linearmotion at the feed end of the shaker processes a higher maximum fluidflow rate, while the more elliptical motion at the discharge end of theshaker conveys sticky clays better. Elliptical motion is effected byusing different weights on vibratory motors creating a forcedifferential which results in motion perpendicular to the line of forceon the basket and a torque imbalance which makes the basket rotate aboutthe center of mass producing elliptical motion; and/or such motion isproduced by varying motor position with respect to the center of mass.In a shaker according to the present invention an operator can manuallyswitch the shaker motion profile between linear, elliptical, andcircular motion (with appropriate motor location and/or spacing and/orwith a motor at the basket center of mass). In another aspect, a shakeraccording to the present invention has the ability to produce all threestandard motions (linear, elliptical, and circular), and a custom motion(change shape front to back on the basket), then the best motion profilecan be chosen based on the mud state and shaker state. For instance, ifthe mud flow rate is very high, linear might be the best motion profile.If very sticky clays are encountered, then circular motion might bepreferred. If the mud does not have a large amount of sticky clays, andthe flow rate is not extremely high, then elliptical motion might bebest. Other conditions may point towards one motion as being the best ata certain time. For instance, an intelligent shaker according to thepresent invention can choose the appropriate motion, and turn motors onand off, or run the motors forward or reverse to achieve the bestmotion. Motors can have brakes applied to stop the rotation of the motorweights in order to achieve the desired motion.

Currently, many prior art shakers run at a fixed or at leastinfrequently changing state. The shaker state can be described by suchparameters as screen mesh, acceleration amplitude, motion profile,basket angle, angle of attack, and vibration frequency. In addition,many typical shakers operate without knowledge of the state of thedrilling mud. Some of the parameters that contribute to the mud stateinclude viscosity, temperature, flow rate, fluid level in the shaker,specific gravity, solids content, and stickiness of the solids.Typically, many prior art shakers are designed to operate at a nominalshaker state that works reasonably well over a range of mud states.Experienced operators change the shaker state periodically to increaseperformance for the current mud state. Prior art mud sensors sense suchparameters. Inexperienced operators may operate the shaker at asub-optimal state for the conditions of the mud.

Even experienced operators may not have the time to change the state ofthe shaker to match changing mud conditions. A shaker supplied withinformation about its own state and the state of the drilling mud canoperate closer to optimum for given conditions. Certain shakersaccording to the present invention measure their own performance toassist in optimizing operation.

In order to operate intelligently, a shaker according to the presentinvention has a computer or other programmable apparatus of some form toread state information, make decisions to optimize performance, andimplement the decisions (e.g., but not limited to, a controller 330,FIG. 10E; control apparatus 550, FIG. 11A, computer 560, FIG. 13; orcontrol apparatus 630, FIG. 14). The computer, in one aspect, isconnected to an I/O (input/output) device or devices that read valuesfrom various sensors and send outputs to actuators, motor drivers,and/or other equipment. Sensors (e.g. sensors within a shaker,container, tank and/or in a flow line or conduit; e.g. sensors 60 and273, 276 of FIGS. 2A and 9) indicate and measure some or all of the mudstate parameters.

With information about the mud state, the current shaker state, and/orother performance measurements, an intelligent shaker according to thepresent invention controls its own state to enhance and/or to optimizeperformance. Shaker states that can be controlled (with user selectablecontrols and/or automatically based on sensor readings) include basketangle, acceleration magnitude, motion profile (linear, elliptical, orcircular; e.g. detect non-sticky free-flowing material and use linearmotion; e.g. detect sticky clays, change to elliptical motion or detectflow is low for a long time and change to elliptical motion), vibrationfrequency, angle of attack (angle of basket motion relative to itshorizontal position; e.g. change center of mass of basket and/or motorlocation).

In certain aspects, the automatic boost feature is a specific instanceof controlled acceleration. In this case, the shaker acceleration istemporarily increased to a pre-determined value, e.g. in order toaccommodate unusually high mud flow. More generally, when the shakeracceleration is controlled, then it can be varied over a continuousrange [e.g. for such control a monitoring device monitors anaccelerometer on or connected to a shaker basket and the monitoringdevice (e.g. a computer, PLC, or PID controller) sends a signal to aVFD). For instance, the acceleration can be controlled to be constantunder varying mud flow/loading. This is accomplished by measuring thebasket acceleration with an accelerometer located on the basket, in oneaspect near the center of mass, e.g. accelerometer AC in FIG. 11C;feeding back the signal from the accelerometer to a shaker computer (orPID controller, or to a remote computer); comparing the actualacceleration with the desired value; and changing the motor frequency orother driving force until the actual acceleration matches the desiredacceleration.

If a desired acceleration value is changed according to the states ofthe shaker and mud, then performance is further enhanced and/oroptimized. For instance, the acceleration level is adjusted to minimizeenergy consumption, or to use the minimum necessary acceleration basedon the fluid level in the shaker. This is useful since high accelerationcan lead to decreased screen life and solids degradation. If the fluidlevel in the basket increases above the desired level, then the basketangle is decreased to tilt the basket uphill. This can only be done to acertain point. Once the basket is fully uphill, the acceleration isincreased, which processes more fluid and lowers the fluid level in theshaker basket.

For condition-based maintenance, the shaker machine state and/or shakerhistory are used to predict when to perform maintenance on the machine.The maintenance schedule of a standard shaker often requires addinggrease to the vibrator motor bearings after a period of time. Dependingon how much the shaker was actually operating over this time causes theactual maintenance time frame to differ from the static, documentedschedule. Proper greasing is especially important to motor bearings(e.g. bearing apparatus BA shown in dotted lines in FIG. 11C). Toolittle grease can cause increased friction, increased temperature, andpremature bearing failure. Too much grease can cause increased pressurein the bearings, increased temperature, and premature bearing failure.Further, the ambient temperature that the motor operates in will affectthe maintenance schedule. Other factors include motor force.

One factor that can be used to predict when bearing grease needs to beadded is the operating temperature of the bearing. According to thepresent invention the bearing operating temperature is sensed with asensor (e.g. sensors in the motor adjacent the bearings, e.g. sensor SR,FIG. 11C) and is then sent to a computer that compares it to the ambienttemperature and the desired temperature level for greasing, then theoperator can be notified (e.g. by any controller as described herein)when it is time to grease the motor bearings. Also, a computer (on theshaker, on site, or remote) or other device is used to keep track of themotor's operational time. When the operational time reaches the desiredmaintenance time, the operator is notified of the required maintenance.This operational time can be adjusted according to the ambienttemperature and current bearing temperature.

Certain shakers according to the present invention have interfaces andcommunications with on-site and remote controllers, computers, systems,networks, and/or the Internet. An automatic shaker according to thepresent invention has a web (e.g. Internet) interface between on-sitepersonnel at the shakers location and personnel and/or computerizedinformation remote therefrom for maintenance and/or re-programmingoperations. This enables technicians during setup, maintenance, ortroubleshooting to monitor the status of the shaker, including allprogram parameters, and adjust the program parameters on the fly, whilethe shaker is shaking and the software is running Additionally, thetechnicians can load software updates to the shaker. The softwareupdates can be accomplished either through the web interface, or byphysically changing a programmable media, e.g. a removable Compact Flashcard. Such a shaker can have a local Ethernet network in its computerenclosure on the shaker. With a wireless radio attached to the shakercomputer network, the shaker computer can communicate wirelessly throughthe closed explosion-proof enclosure with the Internet and/or to alaptop (see, e.g. laptop LAP shown schematically in FIG. 26) with awireless network connection. In one aspect, this works up to about 20feet from the shaker while the shaker is running The range can beextended with the use of a window in the computer enclosure, or with theuse of an antenna in an explosion-proof enclosure with a glass dome.Additionally, the technician can connect to the computer network with anetwork cable.

In certain aspects, a shaker according to the present inventionwirelessly connects to the Internet through a drilling rig's networkconnection. This enables remote monitoring, troubleshooting, andcontrol. For instance, if a rig has a problem, technical support iscontacted and is able to view the shaker state, view program variables,change settings, and update the software remotely, from anywhere in theworld with an Internet connection.

The software in the shaker computer, in certain aspects, has the abilityto be upgraded to communicate with other Drilling Equipment (DE)machines such as tele-operated drilling chairs, Drawworks, rackers, mudcontrol equipment, and top drives. Optionally, local and/or remote userinterfaces with touchscreens are provided. These allow an operator toview more information about the state of the shaker, including alarms,warnings, health checks, and suggested changes to the shaker. Suggestedchanges to the shaker can include increasing or decreasing the screenmesh, greasing motor bearings, replacing sensors, or checking basketangle actuators.

In certain embodiments, (see, e.g. FIGS. 18-28) systems according to thepresent invention provide tests, checks, and intelligent diagnosticsspecific to oil rig operational scenarios, to vibratory separatoroperation and, in particular aspects, to shale shaker operationalscenarios which enhance oil rig safety and efficiency of oil fielddrilling operations, in certain particular aspects when applied to anautomatically operated shale shaker with an electronic and/orcomputerized control system to ensure continuous and proper systemavailability during downhole operations. In certain systems according tothe present invention failures, performance degradation and/or predictedfailures are reported to service personnel that perform additionaldiagnostics or dispatch field personnel to replace or repair the systemsas necessary.

The present invention provides a method and apparatus for remotelymonitoring, analyzing and affirmatively notifying appropriate personnelof problems and events associated with an oil recovery system comprisingone or more, e.g. hundreds, of oil rigs over a vast geographic area. Thepresent invention provides a monitoring and reporting system that isreferred to as a Health Check system. The present invention provides avariety of performance monitoring sensors at each oil rig in an oilrecovery system, and, in certain aspects, for each shale shaker of anoil rig. The results of selected diagnostics, which are run on each oilrig and/or on each shaker, are reported to a central server. The centralserver automatically populates a database for the oil recovery systemand displays a red/yellow/green/gray color-coded report for each rigand/or for an entire oil recovery system. The present invention alsoaffirmatively alerts appropriate personnel of actions required toaddress events associated with an oil rig in an oil recovery system. Thediagnostics performed at each oil rig are configurable at the individualrig. The central server need not change its reporting and displayprogram when changes are made to a heath check at an oil rig. Thepresent invention provides a dynamic oil rig status reporting protocolthat enables construction and display of a tree node structurerepresenting an entire oil recovery system status on a single screen.Preferably, top level information is presented on a single screen, anddetailed information presented when one drills down in to other screens.Thus, the present invention enables rapid visual affirmation of a systemHealth Check.

A Health Check is an automated test that is running on the rig andmonitoring something, e.g., but not limited to, a shale shaker orshakers, for acceptable performance, indication of problems, etc. Thesetests could be applied to equipments, drilling processes, or anoperator's usage of particular drilling equipment, e.g., but not limitedto, shaker(s). The results are then communicated to a central serverlocated in a service center through a unique protocol, which allowsautomatic distribution and display of information and/or directly from ashaker to an Internet interface. A test program on a rig can be modifiedand that change will flow automatically through communication, storageand display of the resulting Health Check data for the rig.

The service center based web server allows secure access to Health Checkresults. The results are presented in “top down tree” mode withred/yellow/green/gray colors. The red color indicates the failure of atest or flagging an event of interest, the yellow color indicates thatthe health test has found some abnormality that may need attention,green indicates successful completion of a test, and gray colorindicates inability to conduct a test. The bottom-most node of the “topdown tree” contains the results of a Health Check. The work-case resultis successively carried up to the next level, until topmost node (whichin most cases is the drilling rig, group of rigs or oil recovery system)is reached.

Each Health Check result can be configured to generate a message (email,phone call, PDA, etc.) to alert single or multiple persons in case oftest failure. The data transfer protocol is well defined, such thatother development groups or third parties can easily develop HealthCheck tests, generate results and feed information to the centralserver. Test results are transferred from the rig to the server using anovel data protocol that dynamically defines the structure of the data,that is, the node tree structure of the data by the naming convention ofthe protocol. Thus, the results are simply stored and displayed usingthe structural definition provided in the communication protocol. Thisallows for extreme flexibility in the definition of new programs andresults to run and report at oil rigs without requiring a change in thecommunication protocol, notification function or the display and storagefunctions at the central server. The bottom-most nodes in the treestructure contain test results. Each test comes into the central serveras a record containing node information as to where the information fitswithin the tree structure, an identifier for the test, a test result(red/yellow/green/gray) and intermediate data such as error codes,operator entry data and test data description. Thus, no resultsprocessing need occur at the central server. The central server onlyarchives and display results and issues affirmative (withacknowledgement) and regular notifications as required.

Events or conditions can be set for notification, thus, once the eventor condition occurs and after it is set for notification, a notificationis sent to a designated person reporting the event of condition. A listof persons can be associated with each oil rig and event or condition. Anotification can be sent to a cell phone, PDA or other electronicdevice. A notification can comprise a text, audio or video message to auser. A notification tells the rig status color code, text, aural orvideo. A user can call into the central server to check the status of anoil rig or oil recovery system. The status returned is a notificationmessage indicating that the rig is okay or that a problem or conditionof interest has occurred. Thus, the Health Checks are different thanalarms, although alarms (including those alarms generated by prior orlegacy systems) can be used as inputs to a Health Check where the alarmsare processed and considered by Health Check rather than sending analarm immediately to oil rig personnel. Health Check may indicate thatpiece of equipment is out of range and should be replaced in the nearfuture, however, supercritical alarms can be processed by Health Checksto generate an immediate notification.

In certain aspects, the present invention (and any and all steps and/orevents described above for any scenario) is implemented as a set ofinstructions on a computer readable medium, comprising ROM, RAM, CD ROM,Flash or any other computer readable medium, now known or unknown, thatwhen executed cause a computer or similar system to implement the methodand/or step(s) and/or events of systems and methods according to thepresent invention, either on-site or remotely or both.

The present invention is described herein by the following example foruse on drilling rigs, however, numerous other applications are intendedas appropriate for use in association with the present invention.

The present invention provides a user interface, which, in one aspect,is preferably mounted to existing rig floor structure and also providesa pedestal mount with adjustable height, for convenient choke operation.A wireless version is also provided.

The present invention supports real-time two-way data communication,e.g., with Varco International, Inc.'s RigSense and DAQ JVM, and withother commercially available information systems. In one aspect anysensors whose data is used by the present invention (for control and/ordisplay) are directly connected to the present invention, including, butnot limited to, sensors on a shale shaker or shakers.

In one aspect, when the RigSense system is present in an embodiment ofthe present invention, the RigSense system provides data archiving andexpanded data displays functionality to the present invention. Thepresent invention provides a user interface integrated into othersystems such as the RigSense system, DAQ JVM and VICIS; Real-Time WellControl, supervisory control specific to well control tasks; andAutomated well control, which may be entire process or selectedsub-tasks. One of the primary impacts perceived on existing products andservices in which integration and/or implementation of the presentinvention is performed is additional capability for taking control ofand/or being in control of the choking operation via a distinctintervention, so that control is clearly being exercised by users atother stations and by automated controllers.

A key factor for efficient utilization and integration of the presentinvention into the operator's working environment is the presentinvention's provision of manual controls for high-frequency user controlactions in lieu of touch screen control consoles. Additional automatedfunctionality is provided such as automatic pressure-set control for usein association with the touch screen and provides benefit in the controlarea, particularly in emergency stations. In an alternative embodiment atouch screen user interface is provided.

In another embodiment, the present invention is implemented as a set ofinstructions on a computer readable medium, comprising ROM, RAM, CD ROM,Flash or any other computer readable medium, now known or unknown thatwhen executed cause a computer to implement a method of the presentinvention.

The present invention provides a method and apparatus for remotelymonitoring, analyzing and affirmatively notifying appropriate personnelof problems and events of interest associated with an oil recoverysystem comprising one or more, e.g. hundreds, of oil rigs over a vastgeographical area or a single rig. The present invention provides amonitoring and reporting system that is referred to as a Health Checksystem. The present invention provides a variety of performance, processand equipment monitoring Health Checks and equipment sensors at each oilrig in an oil recovery system. The present invention provides a dynamicoil rig status reporting protocol that enables population and display ofa tree node structure representing an entire oil recovery system orsingle oil rig status on a single screen. Thus, the present inventionenables rapid visual or aural affirmation of a system Health Check.

Health Checks are not the same as alarms. An alarm is an immediatenotification to an operator that a known unacceptable condition has beendetected, requiring the operator's awareness of it and often some actionby the operator. A Health Check may use alarms in its logic, but it isby nature different than an alarm. A heath check is more general andmore diagnostic than an alarm, and does not require immediate action, atleast not on the oil rig. In the present invention, a problem isreported to a central server for reporting and diagnosis to servicepersonnel. A Health Check can apply to any equipment component orprocess, sensors, control systems, operator actions, or controlprocesses, etc.

The Health Check system comprises software containing test logic. Thelogic is configurable so that inputs, outputs and logic can be selectedby a user to test and look for any condition or event associated with anoil rig or oil recovery system. The overall system in certain aspectscomprises Health Checks running in real time on a computer at an oil rigand a communications network connecting the oil rig to a central serverto move data from the rig of a group of rigs to the server. The serverdisplays the results in hierarchical form. The server sends commands,application programs and data to the rig from the server.

The Health Check system of the present invention further comprises, incertain aspects, a central database populated with dynamic statusreported from oil rigs comprising an oil recovery system. The presentinvention further comprises a web page display for efficientlydisplaying Health Check results associated with a test, a rig, an areaor an oil recovery system. The web page results can be displayed on acomputer, cell phone, personal data assistant (PDA) or any otherelectronic display device capable of receiving and displaying orotherwise alerting (e.g., sound notification) a user of the status ofthe data. The preferred screen is a color screen to enablered/green/yellow/gray display results. Results can also be audio, videoor graphically encoded icons for severity reports, e.g., an audiomessage may state audibly, “situation green”, “situation red” or“situation yellow” or display a particular graphical icon, animation orvideo clip associated with the report to demonstrate a Health Checkseverity report. The present invention enables drilling down (that is,traversing a hierarchical data structure tree from a present node towardan associated child or leaf node), into a tree of nodes representingdiagnostic status, to a node or leaf level to access additionalinformation regarding a color-coded report.

The present invention also provides a notification system to immediatelyinform service personnel of problems as necessary, such as a message oremail to a cell phone or pager or computer pop up message. There is alsoa receipt affirmation function that confirms that a notification messagewas received and acknowledged. Secondary and tertiary notifications aresent when a primary recipient does not acknowledge an affirmativenotification within a configurable time limit. A severity reportassociated with a given problem is represented by a blinking color whenit is unacknowledged and remains a blinking color until the givenproblem is cleared and returns to green or clear status. Severityreports once acknowledged change from blinking to a solid color. Reportsthat have been acknowledged by one user may be transferred or reassignedto another user upon administrative permission by a system supervisor orby requesting permission to transfer a second user and receivingpermission from the second user. A system supervisor can also display alist of users and severity reports being handled by the user, that is, alist of acknowledged and in progress severity reports assigned to aparticular user to view and enable workload distribution to facilitatereassignments for balancing the work load.

A dispatch may assign a work order to a group of particular severityreports. Once the work order is completed the system checks to see ifthe nodes associated with the work order have been cleared. The workorder provides a secondary method for determining if nodes associatedwith a work order have been cleared after a work is complete. The systemadministrator software program can also automatically check the workorder against the node state for a system check.

The advantages provided to the customer of a preferred Health Checksystem are substantially less down time due to the present invention'sHealth Check's ability to find or anticipate problems earlier and fixingthe problems faster, ideally before the customer becomes aware that aproblem has occurred. The present invention reassures the customer thatthe Health Check system is always on the job and monitoring andreporting on the oil recovery system twenty-four hours a day, seven daysa week. A customer or system user can always call in and confirm thestatus of an entire oil recovery system or single rig with a single callto the central server or a rig and receive a situation report, that issituation red, yellow, green or gray for the oil recovery system orsingle rig, as requested. The present invention enables more efficientuse of operational service personnel. The present invention finds andreports problems, potential problems and trigger events of interest,which enables rapid response and recovery in case of actual and/orpotential equipment or operator malfunctions or the occurrence of aparticular event. The present invention also helps to find problems atan early stage when the problems are often easier to fix, beforecatastrophic failure, thus creating less impact on the customer's oilrecovery system or individual oil rig. Health Checks according to thepresent invention provide a method and apparatus for providing anapplication program that acts as an ever-vigilant set of eyes watchingan entire oil recovery system or single rig to ensure that everything isokay, that is, operational.

In certain embodiments, all results for each oil rig in an oil recoverysystem or individual oil rig or equipment, e.g., but not limited to, ashaker or shakers, are worst-case combined so that the worst-caseseverity report bubbles to the top of the reporting tree and is reportedas the status for an entire oil recovery system, oil rig(s), event ofinterest, process, or equipment being analyzed. As discussed above, redis a worst-case severity report, followed by yellow severity report andthen green is the least severe report. Gray indicates no data available.Thus, if one or more tests reporting a red status is received from anoil rig, the red status bubbles up past all yellow and green statusreports and the status for the rig and the entire oil recovery system inwhich the rig resides is shown as red. Once the red report is cleared,yellow reports, if any, bubble up and the status of the oil recoverysystem, rig or equipment being viewed is shown as yellow, if a yellowreport is in a node tree transmitted from any oil rig in an oil recoverysystem. The status for a single oil rig bubbles up the worst-case reportas well, however, localized to the single rig or rigs underinvestigation, unless grouped. When grouped the worst-case status forthe group is reported. For example, if three rigs were reporting thefollowing scenario is possible: Rig 1 reports red, rig 2 reports yellowand rig 3 reports green. The status for a group selected to include rigs1, 2 and 3 would be red. The status for a group selected to include rigs2 and 3 would be yellow. The status for a group selected to include rig3 only would be green. Subsections within a rig can also be selected fora color-coded status report. Preferably, the gray is not cleared.Usually, if the test were not conducted for any reason, the status wouldtake gray color.

The present invention enables testing at the nodes of a bottom up treestructure representing an oil recovery system, a single rig therein, oran equipment in an oil rig, wherein the nodes carry the results to thetop for easy visualization and use. The present invention also providesa dynamic reporting protocol for data transfers from an oil rig to acentral server wherein level identifiers are provided to transfer dataand its structure in a single packet transfer, thus enabling dynamicdata base population and display of reports from an oil rig. The resultsare presented on a web page or reported to cell phones, computers,pagers, personal data assistants or otherwise affirmatively reportedother wise to appropriate personnel. In a preferred embodiment, reportsare acknowledged by a first recipient or a second recipient is selectedfor receipt of the report when the first recipient does not acknowledgereceipt, and so on, until a recipient has received and acknowledged thereport. Alternatively multiple recipients may simultaneously get thenotification.

The present invention is automatically scaleable and extensible due tothe modular and dynamic nature of its design. Tests can be easilycreated, added or deleted and parameters added or modified on an oil rigequipment test or Health Check without reprogramming or changing thecentral server's database population, data reporting and data displayapplications. The reporting can vary between broad coverage and specificcoverage, that is, a status report can included data for an entire oilrecovery system comprising over 100 oil rigs and/or specifically reportstatus for a single oil rig of interest concurrently.

The present invention provides early warning of potential and actualfailures and also provides confirmation of product performance andusage. A set of automated Health Checks and diagnostic tests is selectedto run in real time on an oil rig. Status from the test is reportedcontinuously via a communication link between the oil rig and a centralserver. The present invention provides insight and analysis ofequipment, processes and equipment usage on an oil rig. The presentinvention monitors alarms and parameter limits to assess necessaryaction and perform affirmative notification of appropriate personnel.

The present invention provides quick response, real-time monitoring andremote diagnostics of the automation and control systems running on oilrigs comprising a fleet of oil rigs or an oil recovery system to achievemaximum rig performance while maintaining optimum personnel allocation.A service center is connected to the oil rigs through an Internet basednetwork. System experts make real-time data and logged data from the oilrigs available for perusal and analysis in a central facility or atdistributed locations. The web site of the present invention providesaccess to current operational status as well as to historical operationand performance data for each of the rigs comprising an oil recoverysystem.

Health Check tests are configurable so that new tests can be created,added or deleted and parameters changed for execution at an oil rigwithout the necessity of programming. A simple user interface isprovided wherein a user at the central server or at an oil rig canselect a test from a library of existing tests, or create a new testusing a scripting language, natural language interface or pseudolanguage is provided which generates a script defining inputs, outputsand processing logic for a test. The script is compiled and sent to therig for addition to existing Health Checks running on the rig. The userinterface also enables modification or addition and deletion ofparameters associated with a Health Check or test.

Notifications can be an immediate message when a problem is detected oran advisory notification. The notification is sent to expert servicepersonnel associated with the central server or can be directed to aservice manager or local service person closest to the rig needingservice. For each rig and problem type, a particular person or servicepersonnel category is designated for receipt of a notification.Secondary and tertiary backup personnel and personnel categories aredesignated as a recipient for each notification. Affirmativenotifications must be acknowledged by the recipient so that the problemis acknowledged and someone has taken responsibility for the problem. Ifan affirmative notification is not acknowledged within a configurabletime period, then a secondary or tertiary recipient is notified untilthe problem is acknowledged. Reliability reports are generated by thepresent invention showing performance summaries for oil rigs, comprisingup time, response, problems detected and solutions provided. Thesereports provide an objective basis for formulating an evaluation of theHeath Check system's efficiency.

The results from a rig include processed inputs from the rig. Noprocessing is required at the central server, other than display,storage and alerts to appropriate personnel. The oil rig Health Checksand tests are configurable so no programming is required to implement anew test or change logic or parameters for an existing test. A fieldengineer or central server personnel can add a new test withoutrequiring a user to perform a programming change. The present inventionprovides a local or remote user interface, which provides a simpleinterface for describing a test and logic. The interface comprises aniconic presentation, pseudo language, script or a natural languageinterface to describe a test's input(s), processing logic and output(s).The user interface interprets a user's inputs and converts the user'sinput into a scripting language. The script language is compiled andsent to the rig on which the new or augmented test is to be performed.The new test is added to a library of tests from which a user may chooseto have run at a rig. Test modules can be deleted, added, parameterschanged, and updated from the oil rig, the central server or from aremote user via a remote access electronic device.

Turning now to FIG. 18, a preferred embodiment of the present inventionis shown illustrating a global overview 200 of all rigs comprising anoil recovery system. As shown in FIG. 18, a map pinpoints geographiclocations of the rigs in the system of interest. A web page display ispresented on a personal computer or PDA. The web page generated by thecentral server presents a geographic view of an oil recovery system. InFIG. 18, rig number 563 (70)2 and rig number 569 (707) are shown with ared status, indicating that a condition or reporting event of interesthas occurred at rig number 563 and number 569. Rig number 569 (706) isin Canada and rig number 563 (711) is in the United States. Rig number571 (709) has a yellow status and rig number 567 (708) has gray status.All other rigs shown in FIG. 18 have a green status. When a system userclicks on rig number 569 (707) or the Canadian region, the display ofFIG. 19 appears. FIG. 19 shows the Canadian region, which includes rignumber 569. Notice that rig number 570 has a green status is nowdisplayed on the more detailed Canadian region display. The green statusgeographical indicator for rig number 570 is suppressed and not shown inthe broader display of FIG. 18 so that the more severe red status of rignumber 569 would be immediately visible and evident on the display ofFIG. 18. Once a user implicitly acknowledges the red status for rignumber 569 by clicking on rig number 569, the present invention displaysthe less severe status of rig number 570. Thus, the more severe statusof rig number 569 bubbles up in the geographical display and isdisplayed first at a higher level in the geographical display hierarchy.Note that the green status indicator of rig number 570, however, isshown in the panel 704 of FIG. 18 and FIG. 19. Thus, the presentinvention presents a hybrid display in which all Health Check resultsare available in the panel 704, but worst case results are presented inthe geographical displays of FIG. 18 and FIG. 19.

Turning now to FIG. 20, the status display 724 of FIG. 20 for rig number569 is shown when a user clicks on rig number 569 in FIG. 18 or FIG. 19.FIG. 20 illustrates that a rig number 569 component, “RigSense” has ared indicator. The Magnifying Glass icon 722 shown adjacent redindicator 730 indicates that more information is available regarding thered indicator 730. Notice that there are also additional panel displays716 and 718, which are configurable, which perform additionalinformative functions. A summary panel 720 is displayed for rig number569. The summary status panel contains operator reports from the oilrig. These operator reports are useful in diagnosing status andformulating a plan of action or notification. An AutoDriller statuspanel is also displayed. Note that the Weight on Bit (WOB) indicator 717is red in the AutoDriller status panel. A driller adjustable parameterspanel 718 is also displayed.

Turning now to FIG. 21A, continuing with rig number 569, clicking on thered indicator for RigSense status in FIG. 20, brings up the display forthe RigSense system panel status 740 as shown in FIG. 21A. Note that thedevice message block 743 may contain a part number to expedite repair ofa failure as reported. The particular part number and or drawing numbernecessary to perform a given repair associated with a given problem orseverity report may be difficult to find in a vast inventory of partsand part numbers and drawings associated with a given failure.Otherwise, the recipient of a failure report may have to search via keywords through a vast inventory of parts, part numbers and drawingsassociated with a given failure. Moreover, the user may not be familiarwith a particular vendor's part numbering system, thus, provision of thepart number is a valuable expedient to trouble shooting.

FIG. 21A shows that the sensor group device status 742 is red with aMagnifying Glass icon 746 indicating that more information is availablefor the red sensor group device status indicator 742. In an alternativeembodiment, as shown in FIG. 21B, a pop-up message 746 a appears alongwith the Magnifying Glass stating “Click on Magnifying Glass for moredetails.” Clicking on the red sensor group 744 device Magnifying Glass746 brings up the display 750 of FIG. 22, showing a detailed status forthe sensor group device status. Note that there are two red indicatorsshown in FIG. 22 for device status in the sensor group as follows: “Pump3 Stroke Count Sensor” 756 and “Hookload Sensor” 754. Note that the Pump3 red device status indicator has an informational comment 752 in theoperation column of the display of FIG. 22, stating “Intermittent Lossof Signal.” The Hookload Sensor red device status indicator present anadjacent Magnifying Glass icon 758 with a message indicating that moreinformation is available for the device status of the Hookload sensor byclicking on the Magnifying Glass icon. Clicking on the Magnifying Glassindicator 758 for the Hookload sensor brings up the Hookload sensorpanel 766 of FIG. 23, which shows that the device name “Barrier” 760 hada red device status indicator 762. The red device status for the Barrierdisplays an Operation message 764, stating, “Excessive ground current”.Each colored indicator and accompanying operation message shown in thepreferred displays illustrated in FIGS. 18-23 appeared in line of theHealth Check performed at an oil rig and sent to the server in thestructured protocol of the present invention.

FIG. 24 illustrates a Driller Adjustable parameters display 710 with twored indicators showing that Drill Low Set Point 712 and Upper Set Point714 are Outside Range. A Drilling Tuning parameters panel 716 is alsodisplayed. Both panels indicate the current value, changed indicator andoutside range indicator for each parameter displayed in the respectivepanels of FIG. 24. The display of FIG. 24 is an alternative tabulardisplay for rig status for a single rig. FIG. 25 illustrates aconfiguration or driller adjustable parameters status panel 810 for rignumbers 178-189. The display of FIG. 25 is an alternative tabulardisplay for rig status for plurality of rigs, e.g., rigs 178-189.Turning now to FIG. 26, a data acquisition system 801 is shown in an oilrig environment connected to a plurality of legacy or Heath Checksensors (“SENSORS”) which, in certain aspects, include sensors on ashaker or shakers, which gathers data from the group of sensorsmonitoring the rig equipment, parameters and processes. The dataacquisition system 801 sends the acquired data from the sensors to acomputer 804 on which the preferred Health Check application of thepresent invention is running. The application of the present inventionperforms Health Checks logic on the acquired data and reports theresults in the structured protocol to a user via satellite 806 or someother form of electronic communication. A user may monitor health checkstatus and receive notifications via an electronic receiver 808,diagnostic station 807 or mobile in field service vehicle 805.Alternatively the shaker(s) may have a direct connection from a shakercomputer CPR to the data transmission system.

The present invention is also useful for Process Monitoring, that is, todetermine that equipment is being used properly to perform a designatedprocess. For example, if rig operators are using an “override” during acertain system state indicative of a certain process, which is supposedto be run automatically rather than manually overridden, the presentinvention can perform a health check to detect this event of interestand report it to the central server. Knowledge of this occurrenceenables central server personnel to detect and correct the inappropriateaction of the operators. Moreover, the test to detect the inappropriateoverride stays in the system so that if new operators recreate theproblem or trained operators backslide into using the manual overrideinappropriately, the central server personnel will be notified so thatthe problem can be address again. Thus, the Health Check system builds acumulative base of operational checks to insure that a process on a rigor oil recovery system runs in optimal fashion.

Turning now to FIG. 27, FIG. 27 is an illustration of a preferred HealthCheck system reporting health checks of multiple equipments, processesor systems from multiple oil rigs to multiple users. It is to beunderstood that any equipment's, device's, or apparatus's controller orassociated computer may be employed for the system as shown in FIG. 27,but the specific item shown schematically is a controller and/orcomputer for a shaker. As shown in one aspect the shaker controllerand/or computer is in communication with a Rig Health Commander, aHealth Check Engine, and a user. Optionally, the shaker controllerand/or computer can be in direct communication via the Internet or asimilar network with another entity, device, and/or user.

Turning now to FIG. 28, the results of the tests are reported to thecentral server in a special protocol that contains heath check resultsdata and describes the manner in which the data is constructed so thatthe data can be placed in a logical data structure or tree format anddisplayed. Note that the root node 810, usually an oil rig has adesignation of “00”. The first level of nodes 812, 813 etc. under theroot node are named Aa, Ab, Ac, Ad, etc. Each subsequent layer of nodeis named with the name of the parent node followed by a designation ofthe current node. For example, as shown in FIG. 28, for a rig number569, the root node 810 is named “00”, the first level of children nodesunder the root node are named Aa 812 and Ac 813. The children of node Aa812 are named AaBa 814, AaBd 1116, AaBe 818 and AaBf 820 as shown. Thechildren of child node AaBa are named AaBaC1 822, AaBaC2 824, AaBaC3 826and AaBaC4 828. The children of node AaBaC5 830 are named AaBaC5Dg 832,AaBaC5Dp 834, AaBaC5Dq 836 and AaBaC5Ds 838. A new test could be addedto rig 569 number and the Heath Check status could be reported undernode AaBaC5Dx 840.

Changes to the Health Checks running on any or all rigs does not requirechanges to the display or data base population application because thepreferred communication protocol defines the data base layout anddisplay layout. The leaf nodes of the tree structure represent HealthCheck results. Each node contains a test identifier, test result(red/yellow/green/gray), intermediate data, user-entered data and testdescription. Trouble shooting comments are provided at the centralserver based on reported errors. Test error codes are included in thenode so that messages associated with the error codes are displayed tothe appropriate user. Alternately, trouble shooting and otherinformation can also be generated and appended to the results of thetests at rig site.

Thus, no processing to determine rig status is done at the centralserver. Notifications are sent when deemed necessary by the application.Notification logic is configurable by service personnel at the centralserver or at the oil rig. Notification logic dictates that notificationsare sent when an event occurs and the event has been selected forreporting as a notification to a user. The notification logic and a listof appropriate notification recipients in order of priority, that is,who to contact first, is retained at the central server. The event canbe a report on an equipment status, process execution or an operationalitem. A user can check in with the central server of present inventionto obtain a real time report of the status of an oil rig or multiple oilrigs. The requesting user will receive a severity report messageindicating the status of the rig, for example, “okay” or“red/yellow/green/gray.”

FIGS. 29-32B illustrate computer screen displays for one embodiment of acontrol system for shakers and methods of their use according to thepresent invention.

FIG. 29 shows a display screen provided by a server, e.g. a web serveron a computer on a shaker (e.g. like the computers 530, 630 and theshale shaker computer controller in FIG. 27). When this computer isconnected to and in communication with a rig control system, interfaceswith the rig control system are identified as “Alarms & Events,”“Diagnostics,” and “Documentation.” From the “General” column, anoperator can go to any of the five listed choices. Choosing “DebugMonitor” leads to a display screen as in FIGS. 32A and 32B that allows auser to monitor and modify shaker program variables. Choosing“Administration” leads to a display screen as in FIG. 30. “ArrayManipulator” leads to a screen that shows the array of input/outputchannels. “Software versions” leads to a screen that displays thecurrent software version. “Log Manager/Viewer” leads to a screen thatallows the user to view and delete system log files.

The display screen of FIG. 30 [displayed by clicking on the “DebugMonitor” line, FIG. 29 illustrates a variety of administrative checksand tasks that can be done related to the shaker computer. “Restart JVM”is chosen to restart the computer software operating system on theshaker computer. The shaker control program is stopped by choosing “StopController.” This screen lets a user choose which parameters andvariable are viewed (e.g. in screens like screens in FIGS. 32A and 32B).The general state of the shaker is displayed by choosing“ControlStation.” Choosing “Timer” displays timer variables and states.The “ai” screen displays analog input variables and states, e.g. fromthe ultrasonic transducers, the measured distance to fluid on thescreens. Controller variables and states are displayed by choosing“controller.” Digital input variables and states [e.g. signals from ashaker's variable frequency drive] and those effected using user pushbuttons and switches (e.g. as in FIG. 14) are displayed by choosing“di.” Digital output variables, e.g. valve opening and closing signalsand signals to a VFD to run fast or fun normal, are displayed bychoosing “dq.” Parameters and variables of the protocol used to send andreceive information is displayed by choosing “modbus.”

In FIG. 32A the entries indicate the following:

Entry Indication actuatorState state of actuator (e.g. 636, FIG. 14) -moving up, moving down, stopped autoOrManualModeState auto control oruser control of basket angle fluidLevelState pool depth on screenrelative to desired position - high, low, desired fluidFlowStaterelative fluid flow rate onto shaker screens basketAngleState basketangle - home position, intermediate, high commandState command outputsent to actuator system - main timer waiting, null, actuator moving up,actuator moving down controlState state of sensor reading timer cycle -waiting, reading fluidFlowNoFlowCounter number of consecutive timesfluid flow sensor has measured a no-flow fluidFlowNoFlowMaxCount presetnumber of consecutive times flow sensor must measure no-flow beforebasket angle is moved to fully uphill position to prepare for next fluidrush sensorReadCounter current number of times sensors have been readsensorReadCounterMaxCount number of sensor readings to take, filter, andreturn a signal value motorMotionState current shaker motion - linear,elliptical, circular motorSpeedState speed of shaker motors - normal,boost boostConditionsMetCounter number of consecutive times boostconditions have been met boostConditionsMetCounterMax number ofconsecutive times boost conditions must be met before motor speed isautomatically boosted fluidLevelDataState indication whether sensorreading are within expected range - in scope, out of scopefluidLevelValidSensor indicates % of sensor reading within expectedDataPercentage range fluidFlowDataState whether sensor readings arewithin expected range - in scope, out of scope fluidFlowValidSensorindicates s$ of sensor reading within expected DataPercentage range

In FIG. 32B, the entries indicate the following for each of threedifferent sensors (ultrasonic transducer apparatuses):

Entry Indication deadband distance above or below desired value thatwill not cause the actuator to move desiredValue desired fluid levelfluidLevelError difference between desiredValue and fluidLevel_inchesfluidLevelInches distance that represent fluid level homePositiondistance to the bottom of the screen at the lowest basket anglemaxValueFiltered maximum allowable filtered fluid level (medianDistance)medianDistance filtered fluid level minValueFiltered minimum allowablefiltered fluid level (medianDistance) offset distance above thehomePosition that represents a high flow runningState pool depth on theshaker screen relative to the desired position - high, low, at desiredvalidSensorDataPercentage the % of sensor readings within the expectedrange validSensorDataPoints actual number of valid sensor readingscalibrateCommand has the calibrate button been pushed decoded is theinput used forceEnabled is the input value controlled by the DebugMonitor forceValue value to force the input to if forceEnabled is trueioIdentifier Modbus address of the input ioType (MOD) Modbus protocolmaxRawValue maximum value that can be returned from the input maxValuemeasurement scale value corresponding to the maxRawValue for this inputminRawValue minimum value that can be returned from the input minValuemeasurement scale value corresponding to the minRawValue for this inputrawValue raw integer value returned from the input

The present invention, therefore, in at least some, but not necessarilyall embodiments, provides a vibratory separator including: a base; abasket movably mounted on the base and for supporting screen apparatusfor treating material introduced into the vibratory separator, thebasket on the base and pivotable with respect thereto; screen apparatussupported by the basket, the material flowing onto the screen apparatusfor treatment; vibratory motor apparatus connected to the basket forvibrating the basket and the screen apparatus; variable frequency driveapparatus for selectively driving the vibratory motor apparatus at aselected speed; angle adjustment apparatus connected to the basket foradjusting angle of the basket; sensor apparatus connected to thevibratory separator for sensing a parameter indicative of operation ofthe vibratory separator for providing a signal corresponding to saidparameter; and control apparatus for receiving signals from the sensorapparatus, for controlling the vibratory separator based on saidsignals, and for automatically signalling the variable frequency driveapparatus to change the speed of the vibratory motor apparatus so thatforce applied to the basket is changed. Such a vibratory separator mayhave one or some (in any possible combination) of the following: whereinthe basket is tilted at a largest possible uphill angle; wherein thecontrol apparatus includes timing apparatus that indicates the baskethas been maintained at the largest possible uphill angle for a pre-settime period and actuation apparatus for actuating the variable frequencydrive apparatus to increase the speed of the vibratory motor apparatusupon said pre-set time being achieved; wherein said actuating is donefor a pre-set period of time or until a pre-set flow of material to thematerial introduction end is sensed by the sensor apparatus; wherein thevibratory separator is a shale shaker and the material is drilling fluidwith drilled cuttings therein; wherein the vibratory apparatus comprisestwo motors for vibrating the basket, the two motors providing dualmotion capability; wherein the sensor apparatus comprises a plurality ofsensor apparatuses; wherein the measurement sensor apparatus is from thegroup consisting of electrical, optical, electromagnetic, ultrasonic,acoustic, and pulse-echo apparatus; flow sensor apparatus connected tothe vibratory separator for sensing the flow of material onto the screenapparatus, the flow sensor apparatus controlled by and in communicationwith the control apparatus, and the control apparatus for adjustingshaker operation in response to signals from the flow sensor apparatus;the vibratory motor apparatus connectible to the basket at a pluralityof locations so that a motion profile of the basket is selectivelyvariable between linear, elliptical, and circular motion; wherein themotion profile of the basket includes a first shape at a materialintroduction end of the basket and a second shape at a material exit endof the basket; wherein the basket has a middle area between the materialintroduction end and the fluid exit end and the motion profile of thebasket includes a thin ellipse shape at the material introduction end, amedium ellipse shape at the middle area, and a fatter ellipse shape atthe material exit end; the vibratory motor apparatus including bearingapparatus for enhancing operation of the vibratory motor apparatus, thesensor apparatus including temperature sensor apparatus for sensingtemperature of the bearing apparatus during operation, and the controlapparatus for providing a notification to an operator of the vibratoryseparator that the bearing apparatus is to be greased; the controlapparatus for monitoring total operational time of the vibratoryseparator and for providing a notification of said total operationaltime; the control apparatus including web interface apparatus for aninterface between on-site personnel at a location of the vibratoryseparator and an entity remote therefrom; the vibratory separator on adrilling rig, the control apparatus for monitoring and analyzing aplurality of signals from the sensor apparatus and for transmittingsignals indicative of information related to operation of the vibratoryseparator to a processor on the drilling rig, the processor including aset of health check rules for health checks comprising logical rules,inputs and outputs for defining events associated with the status of thevibratory separator, the processor for determining a severity code foreach event and for reporting the events and severity codes to a centralserver, the events reported by the processor to the central server in aprotocol defining a data structure, the data structure comprising ahierarchical tree node structure wherein results from application of thehealth check rules are a bottommost node of the tree node structure, anddisplaying the event severity codes on a display; the processor forproviding to the central server the results as records containing nodeinformation regarding an appropriate location for the results in thetree node structure; and/or the control apparatus running the healthchecks in real time to provide results regarding on-going status of thevibratory separator to indicate a potential failure of the vibratoryseparator.

The present invention, therefore, in at least some, but not necessarilyall embodiments, provides a vibratory separator including: a base; abasket movably mounted on the base and for supporting screen apparatusfor treating material introduced into the vibratory separator, thebasket on the base and pivotable with respect thereto; screen apparatussupported by the basket, the material flowing onto the screen apparatusfor treatment; vibratory motor apparatus connected to the basket forvibrating the basket and the screen apparatus; sensor apparatusconnected to the vibratory separator for sensing a parameter indicativeof operation of the vibratory separator for providing a signalcorresponding to said parameter; control apparatus for receiving signalsfrom the sensor apparatus, for controlling the vibratory separator basedon said signals; wherein the vibratory separator is a shale shaker andthe material is drilling fluid with drilled cuttings therein; whereinthe sensor apparatus comprises a plurality of sensor apparatuses; andthe vibratory motor apparatus connectible to the basket at a pluralityof locations so that a motion profile of the basket is selectivelyvariable between linear, elliptical, and circular motion.

The present invention, therefore, in at least some, but not necessarilyall embodiments, provides a method for treating material introduced to avibratory separator, the method including introducing material to avibratory separator according to the present invention, treating thematerial in the vibratory separator, and adjusting the angle of thebasket, its motion profile, and/or its motor speed.

In conclusion, therefore, it is seen that the present invention and theembodiments disclosed herein and those covered by the appended claimsare well adapted to carry out the objectives and obtain the ends setforth. Certain changes can be made in the subject matter withoutdeparting from the spirit and the scope of this invention. It isrealized that changes are possible within the scope of this inventionand it is further intended that each element or step recited in any ofthe following claims is to be understood as referring to the stepliterally and/or to all equivalent elements or steps. The followingclaims are intended to cover the invention as broadly as legallypossible in whatever form it may be utilized. The invention claimedherein is new and novel in accordance with 35 U.S.C. §102 and satisfiesthe conditions for patentability in §102. The invention claimed hereinis not obvious in accordance with 35 U.S.C. §103 and satisfies theconditions for patentability in §103. This specification and the claimsthat follow are in accordance with all of the requirements of 35 U.S.C.§112. The inventors may rely on the Doctrine of Equivalents to determineand assess the scope of their invention and of the claims that follow asthey may pertain to apparatus not materially departing from, but outsideof, the literal scope of the invention as set forth in the followingclaims. All patents and applications identified herein are incorporatedfully herein for all purposes. In the claims, means-plus-functionclauses are intended to cover the structures described herein asperforming the recited function and not only structural equivalents, butalso equivalent structures. Thus, although a nail and a screw may not bestructural equivalents in that a nail employs a cylindrical surface tosecure wooden parts together, whereas a screw employs a helical surface,in the environment of fastening wooden parts, a nail and a screw may beequivalent structures. It is the express intention of the applicant notto invoke 35 U.S.C. §112, paragraph 6 for any limitations of any of theclaims herein, except for those in which the claim expressly uses thewords ‘means for’ together with an associated function.

Whereas the present invention has been described in particular relationto the drawings attached hereto, it should be understood that other andfurther modifications apart from those shown or suggested herein, may bemade within the scope and spirit of the present invention.

What is claimed is:
 1. A vibratory separator, comprising: a basketassembly comprising a screen apparatus, wherein said basket assembly isadapted to be vibrated so as to facilitate separation of a material tobe separated that is introduced to said screen apparatus; a vibratoryapparatus operatively coupled to said basket assembly, wherein saidvibratory apparatus is adapted to vibrate said basket assembly; at leastone sensor apparatus that is adapted to sense a state of said materialthat has been introduced to said screen apparatus; and a controlapparatus, wherein said control apparatus is adapted to adjust saidvibratory separator to vibrate said basket assembly at a first vibratoryseparator setting when said sensed state of said material is at a firstsensed state by adjusting an acceleration of said basket assembly to afirst preselected acceleration level based on said first sensed state,wherein said control apparatus is further adapted to adjust saidvibratory separator to vibrate said basket assembly at a secondvibratory separator setting when said sensed state of said material isat a second sensed state that is different than said first sensed stateby adjusting said acceleration of said basket assembly to a secondpreselected acceleration level based on said second sensed state, andwherein said second vibratory separator setting is different than saidfirst vibratory separator setting and said second preselectedacceleration level is different than said first preselectedacceleration.
 2. The vibratory apparatus of claim 1, wherein said atleast one sensor apparatus is adapted to send a signal representing saidsensed state of said material to said control apparatus.
 3. Thevibratory apparatus of claim 2, wherein said vibratory apparatuscomprises a motor apparatus that is adapted to control an excitationforce used to accelerate said basket assembly, and wherein said controlapparatus is adapted to control an operation of said motor apparatusbased on said signal that is received by said control apparatus fromsaid at least one sensor apparatus.
 4. The vibratory apparatus of claim3, wherein said vibratory apparatus comprises a variable frequency driveoperatively coupled to said motor apparatus, and wherein said controlapparatus is adapted to control a speed of said variable frequencydrive.
 5. The vibratory apparatus of claim 1, wherein said controlapparatus is adapted to substantially maintain said acceleration of saidbasket assembly at said first preselected acceleration level until saidsensed state of said material is at said second sensed state.
 6. Thevibratory apparatus of claim 5, further comprising an accelerometeroperatively coupled to said basket assembly, wherein said controlapparatus is adapted to substantially maintain said acceleration of saidbasket assembly by continuously sensing an actual acceleration of saidbasket assembly with said accelerometer and continuously automaticallyadjusting an excitation force applied to said basket assembly based onsaid continuously sensed actual acceleration.
 7. The vibratory apparatusof claim 1, wherein said at least one sensor apparatus is adapted tosense at least one of a flow rate of said material onto said screenapparatus and a level of said material above said screen apparatus. 8.The vibratory apparatus of claim 1, wherein said at least one sensorapparatus is adapted to sense at least one of a viscosity of saidmaterial, a specific gravity of said material, a solids content of saidmaterial, and a stickiness of solids present in said material.
 9. Thevibratory apparatus of claim 1, wherein said control apparatus isadapted to continuously vary an acceleration of said basket assemblybetween said first preselected acceleration level and said secondpreselected acceleration level in response to a change in said sensedstate of said material.
 10. The vibratory apparatus of claim 1, whereinsaid control apparatus is adapted to automatically adjust at least oneof a motion profile, a basket angle, and a vibration frequency of saidbasket assembly.
 11. The vibratory apparatus of claim 10, wherein saidcontrol apparatus is adapted to vibrate said basket assembly using atleast one of a linear, a circular, and an elliptical motion.
 12. Thevibratory apparatus of claim 11, wherein said control apparatus isadapted to vibrate a feed end of said basket assembly using at least oneof said linear, circular, and elliptical motions and to vibrate adischarge end of said basket assembly using a different one of saidlinear, circular, and elliptical motions.
 13. The vibratory apparatus ofclaim 1, wherein said control apparatus is further adapted toautomatically adjust said vibratory separator to vibrate said basketassembly at a third vibratory separator setting when said sensed stateof said material is at a third sensed state that is different than saidfirst and second sensed states by adjusting an acceleration of saidbasket assembly to a third preselected acceleration level based on saidthird sensed state, and wherein said third vibratory separator settingis different than said first and second settings and said thirdpreselected acceleration level is different than said first and secondpreselected acceleration levels.
 14. The vibratory apparatus of claim 1,wherein said control apparatus is further adapted to automatically boostsaid acceleration of said basket assembly to a preselected boostacceleration level that is greater than said first and secondpreselected acceleration levels when at least one of a flow rate of saidmaterial onto said screen apparatus or a level of said material on saidscreen apparatus exceeds a predetermined magnitude.
 15. A vibratoryseparator, comprising: a basket assembly comprising a screen apparatus,wherein said basket assembly is adapted to be vibrated so as tofacilitate separation of a mixture comprising drilling fluid and solidsthat is introduced to said screen apparatus; a vibratory apparatusoperatively coupled to said basket assembly, wherein said vibratoryapparatus is adapted to vibrate said basket assembly; at least onesensor apparatus that is adapted to sense a state of said mixture thathas been introduced to said screen apparatus; and a control apparatus,wherein said control apparatus is adapted to operate said vibratoryseparator at a first separator setting so as to separate said drillingfluid from said solids by vibrating said basket assembly at a firstacceleration level and automatically adjusting an excitation forceapplied to said basket assembly to substantially maintain said firstacceleration level based on said sensed state of said mixture, andwherein said control apparatus is further adapted to automaticallyadjust said operation of said vibratory separator to a second separatorsetting that is different than said first separator setting when saidsensed state of said mixture exceeds a predetermined state byautomatically increasing said acceleration of said basket assembly to apredetermined second acceleration level that is greater than said firstacceleration level.
 16. The vibratory separator of claim 15, whereinsaid control apparatus is further adapted to automatically adjust anexcitation force applied to said basket assembly so as to maintain saidpredetermined second acceleration level and to automatically reduce saidacceleration of said basket assembly from said predetermined secondacceleration level to a third acceleration level when said sensed stateof said material no longer exceeds said predetermined state, whereinsaid third acceleration level is based on said sensed state of saidmixture.
 17. The vibratory separator of claim 15, wherein said at leastone sensor apparatus is adapted to sense at least one of a flow rate ofsaid mixture onto said screen apparatus and a level of said drillingfluid above said screen apparatus, and wherein said predetermined statecomprises at least one of a predetermined flow rate of said mixture ontosaid screen apparatus and a predetermined level of said drilling fluidabove said screen apparatus.
 18. The vibratory separator of claim 15,further comprising an accelerometer operatively coupled to said basketassembly, wherein said accelerometer is adapted to continuously sense anactual acceleration of said basket assembly and to continuously send asignal representing said sensed actual acceleration to said controlapparatus.
 19. The vibratory separator of claim 18, wherein saidvibratory apparatus comprises a variable frequency drive operativelycoupled to a motor apparatus, wherein said motor apparatus is adapted toapply said excitation force to said basket assembly, and wherein saidcontrol apparatus is adapted to substantially maintain said accelerationof said basket assembly based on said signal representing saidcontinuously sensed actual acceleration by controlling a speed of saidof said variable frequency drive so as to continuously automaticallyadjust an excitation force applied to said basket assembly by said motorapparatus.
 20. The vibratory separator of claim 15, wherein said controlapparatus is adapted to control at least one of a motion profile, abasket angle, and a vibration frequency of said basket assembly.